Application of Total Quality Management At Gazi Wires Limited

INTRODUCTION

1.Total Quality Management is a structured system for satisfying internal and external customers and suppliers by integrating the business environment, continuous improvement and breakthroughs with development, improvement, and maintenance cycles while changing organizational culture.
2.One of the keys to implementing TQM can be found in this definition. It is the idea that TQM is a structured system. It is a strategy derived from internal and external customer and supplier wants and needs that have been determined through Daily 3.Management and Cross-Functional Management.
Pinpointing internal and external requirements allows us to continuously improve, develop, and maintain quality, cost, delivery, and morale. TQM is a system that integrates all of this activity and information.

OBJECTIVES

1.To apply the TQM in a production industry. I have chosen Gazi Wires Ltd. as my case study.
2.To determine the improvement of quality of products as well as organizational culture relating to quality improvement.
3.To try to convince other industries to apply TQM.

CONCEPTS OF TQM

The concepts of TQM are as follows:
1.Continuous Improvement
2.Employee empowerment
3.JIT concept
4.Bench Marking
5.Knowledge of Tools

TOOLS OF TQM

The Tools of TQM are:
1.QFD (Quality Function Deployment) or House of Quality.
2.Taguchi Method.
3.Pareto Charts
4.Cause And Effect Diagram (Fish-Bone Diagram).
5.Statistical Process Control (SPC).

PRODUCTION PROCESS
1) Drawing: Annealed wax coated Copper Wire of 8mm diameter is imported and drawn in the drawing machines through polished tungsten carbide dies and Diamond dies for reduction of the cross-section step by step till desired is obtained.
2) Annealing: The Copper Wire becomes undesirably hard on drawing. For restoration of the ductility, the wires are annealed controlled overhead furnaces maintained at a temperature of 500°C to 800°C depending on the size of the wire.
3) Enameling: After passing through drawing and annealing machines, the wires are to be enameled to give further necessary qualities. But all wires are not to be enameled as they have customers for wires without enamel.

TESTS

1)Physical Tests: Heat shock, Heat ageing, Elongation of SECW
2)Electrical Tests: Electric strength, Continuity of Covering
3) Chemical Tests: Cure test, Cut through test
4) Peel Test
5) Mechanical Test: Jerk test

GAZI WIRES ON THE BASIS OF TQM

On the basis of TQM my suggestions for the Gazi Wires Ltd. in the sector of
1.Quality Control Circle
2.Quality of Raw material
3.Quality of Finished Goods
4.Quality Relating Discussion
5.Quality Records
6.Involvement of all
7.Slogan of Quality
8.Bench Marking
9.Machines, Equipment, Servicing
10.Storage and Delivery
11.Performance measure and Motivation
12.Training
13.Meeting with Top Management
14.External Audit
Marketing
16.Customer Satisfaction
17.Productivity
18.Information System
19.Working Condition
20.Relation among Employees

THE BENEFITS OF TQM

1.The initiation of a special study to determine error or defect sources, training needs, etc. This will, of course, initially prevention costs.
2.Special efforts to improve communication at the internal supplier customer interfaces and between departments such as marketing, design, production and purchasing.
3.The continued collection, analysis and reporting of quality related cost information by personnel in finance and quality management.
4.The establishment and maintenance of quality objectives, in terms of Costs, for the entire organization and for specific areas.

Design and Fabrication of a Room Heating System-Effect of Air Velocity

OBJECTIVES

1.To Design and Fabricate a Room Heating system.
2.To observe the rate of Heat Transfer from the system to the atmosphere.
3.To observe the effect of different air velocities in the rate of heat transfer.

EQUIPMENTS

1.Piping system
2.Rota meter
3.Storage Tank
4.Electric Heater
5.Fin

METHODOLOGY

1.Water in the storage tank was heated by an electric heater.
2.Heated water then pumped into the piping system which was attached with some fins.
3.Pumped water then returned back into the storage tank .
4.Heat was transferred to the atmosphere through the piping systems and fins.

VEHICLE CONTROL BY SOFTWARE TO OVERCOME ACCIDENT

OBJECTIVES

1.To design and fabricate a vehicle control circuit.
2.To develop an algorithm to control the vehicle.

METHODOLOGY

1.The host vehicle repeatedly radiating infrared waves in a predetermined range and senses the obstacle with IR sensors.
2.Sensors transmit digital signals to microcontroller.
Microcontroller then decides the movement of the vehicle and signals to the dc motor controller (L298) to control the motors.
3.Two motors are used. One motor at the back position which gives the vehicle forward or backward motion. Another motor is at the front to control the steering to give rotational motion.
4.Programming is done with MikroC compilier.
5.PIC 16F72 microcontroller is used.

OUTPUT
1.When obstacle is in the front, the vehicle stops down with brake and then turns to left.
2.When obstacle is in the right position, the vehicle turns to left.
3.When obstacle is in the left position, the vehicle turns to right.

Construction and fabrication of an automatic sliding door using IR sensor

OBJECTIVES

1.To construct an automatic sliding door
2.To fabricate an automatic sliding door
3.Performance test of the project

IMP0RTANCE

It reduces use of physical effort.
It is easy to operate.
With appropriate arrangement it can be used anywhere.
Durable and safe.

LIMITATIONS

Power supply should be available.
Setting cost is high.
Electrical equipment may be damaged
Sunlight may occur problem

RECOMMENDATIONS

An additional power supply can be included for the absence of mains.
A heavy structure can be obtained increasing power to have a smarter look & more efficient output.
Taking more care of the sensitive devices from the unwanted emissions can augment sensitivity.
Security system can be improved by applying password system, image monitoring, voice controlling etc.

CONCLUTIONS

It provides safety and comfort
Human life becomes easy and luxurious
Effective application
It can be applicable technology in the developing country like us

COMPUTATIONAL STUDY OF TURBULENT FLOW OVER A SPHERE

INTRODUCTION

Computational Fluid Dynamics or CFD is the analysis of systems involving fluid flow, heat transfer and associated phenomena such as chemical reactions by means of computer-based simulation.
It is becoming very popular to solve flow problems without doing any experiment. We can assume practical situation of any flow system without go through the experiment. So it is very economical.

WHY USED CFD?

Analysis and Design
1. Simulation-based design instead of “build & test”
More cost effective and more rapid than EFD
CFD provides high-fidelity database for diagnosing flow field
2. Simulation of physical fluid phenomena that are difficult for experiments
Full scale simulations (e.g., ships and airplanes)
Environmental effects (wind, weather, etc.)
Hazards (e.g., explosions, radiation, pollution)
Physics (e.g., planetary boundary layer, stellar evolution)
Knowledge and exploration of flow physics

APPLICATION OF CFD

1.Aerospace
2.Automotive
3,Biomedical
4.Chemical processing
5.Heat ventilation air condition
6.Hydraulics
7.Power generation
8.Sports
9.Marine etc.

OBJECTIVES
My objectives are to know and analyze the followings:
To know about the basics of fluid dynamics.
To know about the computational fluid dynamics (CFD).
To know the application of CFD.
To know about the point of separation for the turbulent flow over a sphere.
To know about the effect of diameter on the point of separation.
To know about the effect of velocity on the point of separation.
To know about the effect of diameter on the pressure co-efficient.
To know about the effect of velocity on the pressure co-efficient.
To know about the effect of diameter on the skin friction co-efficient..
To know about the effect velocity on the skin friction co-efficient.

CONCLUSION

We choose spherical co-ordinate system(r, θ, ϕ) for the analysis.
Around 680 iterative steps needed for the convergence.
For finding pressure co-efficient and skin friction co-efficient at different angle the range is chosen from 0 radian to π radian.
The velocity vector represents both direction and magnitude of the flow .
Flow separation occurs earlier in case of larger diameter of the sphere.
For higher velocity separation starts early than lower velocity.

DESIGN & CONSTRUCTION OF AN AUTOMATIC GARDEN WATER SPRINKLER

INTRODUCTION
Sprinkler has an established place in gardens and in irrigation and with as many different water effects as possible. A revolving water sprinkler that has single or more arms those revolves and shoots water. By revolving water sprinkler it is very easy for watering in a garden. It saves time, cost and labour.
OBJECTIVES
I would mention the following objectives as my project-
1.Design of garden water Sprinkler.
2.Construction of garden water sprinkle.
METHODOLOGY
I want to follow the following steps-
1.Study of the theory
2.Study of the various types of sprinkler.
3.Design of nozzle.
4.Design of sprinkler.
5.Select the material for nozzle & frame.
6.Construction and testing of sprinkler.

WORKING PRICIPLE
Revolving water sprinkler is constructed based on the basic
theories of fluid mechanics, such as Continuity equation,
Bernoulli’s equation and impulse momentum equation.
A metallic stand which holds the bearing at the top of the stand
and the pipe through water enters the nozzle. The end of the
Nozzle will be bent about 45 degree for maximum throwing of
water & cover maximum area of the garden. The entering water
with high velocity which revolves pipe due to reaction force.
ADVANTAGES
Suitable to all types of soil except heavy clay
Suitable for irrigating crops where the plant population per unit area is very high. It is most suitable for oil seeds and other cereal and vegetable crops
Water saving
Closer control of water application convenient for giving light and frequent irrigation and higher water application efficiency
Areas located at a higher elevation than the source can be irrigated
Possibility of using soluble fertilizers and chemicals

COMPARISON
Revolving Sprinkler: Spraying water at a fixed circle, so it can not cover whole area of the garden.
Impulse or Impact Sprinkler 450 nozzle angle:
Water reaches maximum distance but water leakage is very high.
Impulse or Impact Sprinkler parallel nozzle:
Water can not reach so far, but water leakage is very less.

IMPROVEMENT
For improving the garden sprinkler we have must control the flow of water. So we will be used microcontroller program to control the stepper motor for rotating the sprinkler at different angles to cover the whole area of the garden.
Also we will be controlled the water flow by controlling the solenoid valve with timer.

CONSTRUCTION OF ROTARY LAWN MOWER

INTRODUCTION

The lawn mower is a mechanical device that literally shaves the surface of the grass by using a rapidly rotating blade or blades. It is a grass cutting machine. There are several kinds of grass cutting machine. Some are electro mechanical and some are manual. On this work, I have tried my best to construct an efficient lawn mower and tested it after construction.
ROTARY LAWN MOWER
A rotary lawn mower is a machine that uses revolving blades to cut a lawn at an even length.

OBJECTIVES OF THE PROJECT

1.To study the rotary lawn mower.
2.To construct a rotary lawn mower.
3.To use the mower for cutting grasses in flat land.

METHODOLOGY

1.Making frame.
2.Fitting the wheel with the frame.
3.Installing the motor on the frame.
4.Fitting the cutting blade with the motor shaft.
5.Assembling other necessary components.