Profitability
through
Calibration
Increase your ‘PROFITABILITY’ through “CALIBRATION” How??
REDUCE REJECTION RATIO (3 R PRINCIPLE)
It is a fact. It is not a man-made story. :This was the period when ISO was just coming up in around 1993-94. There was an Auto Component Manufacturing Co. located off the Pune- Solapur Road, near Sahajpur. They were suffering from a large rejection of the order of 45%. After the Heat Treatment, the component was getting rejected in Quality Control Testing.
After lot of searches, they could locate ‘YENKAY’. They approached the YENKAY & narrated the rejection. We‘YENKAY’, visited their site, listened to them and understood the problem. We studied their Heat Treatment Process & guessed the probable problematic area. Asked them to repeat the process but our temperature sensors which we carried AT SITE, WHEN the actual temperature reached to the set temperature ( that was 900°C) , we allowed it to stabilize and then after thermal stabilization, we noted temperature indicated by the instrument & temperature measured with our sensor. There was a difference of around 90°C between these two temperatures. Showed this to concern person the root cause of 45% rejection.
Then calibrated the system & corrected the temperature difference. Again we carried out heat treatment process with new batch after temperature correction. This time to your surprise the rejection reduced to 5%.
By correct calibration the rejection ratio reduced from 45% to 5%. This was only possible with correct calibration. Till date that customer is with us.
INCREASE THE PRODUCTIVITY
Anybody can reply that when rejection get reduced that will give rise to increase in productivity.
REDUCTION OF WASTAGE
when rejection was more (eg. 45%) that mean out of 100 jobs 45 jobs became wastage and when rejection was 5% , naturally the wastage became 5 jobs in place of 45 jobs out of 100.
IMPROVE EFFICIENCY
COST SAVING
Let us take same example The process time lets assume 10 hours. That means the furnace is on for 10 hours. The cost let us say Rs. 50,000/- In both cases, before calibration & after calibration since process time is assuming same, cost also same. In same cost you are getting 95 jobs & in other case you are getting 55 jobs.
IMPROVE QUALITY
when rejection is reduced, it implies that quality of your product is improved. In short, the benefits are
1) Reduction of rejection.
2) Increase the productivity.
3) Reduction of wastage.
4) Improved efficiency.
5) Cost saving
6) Improve quality.
All these factors lead to ‘Profitability’ through Calibration.
