Through this case study, Narayan Joglekar offers practical tips to prevent product rejection and improve productivity

“Sir, I talked to Lobo and explained this job to him at least three times but still he spoiled it. What could I do? ” Satish Deshmukh, my Assistant Engineer, was talking with frustration. I was working as Manager-In-Charge of a large tool room (tool manufacturing) department. The job lying on my table was an essential and intricate part (punch) of an important press tool. This press tool was supplying some essential components for the assembly. The earlier press tool was worn out and broken and the assembly would stop from next week onwards in its absence. I was just gazing in vain at the spoiled job with resentment. “Satish, tell me one thing, what is it that you actually told to this worker three times?” Satish first did not understand the question. Rather he did not expect such a simple but pointed question.

“Well, as usual, I told him that the job was very important and critical. I told him that our works manager is after this press tool and I even told him that the assembly line would suffer if this job is delayed and the blame….” I stopped Satish in between. “But Satish, did you not peacefully explain to him the proper manufacturing procedure and caution him about the pitfalls and possible errors? Did you discuss the inspection procedure? Had you done that, possibly the job would not have got rejected.”

I could see some understanding on his face. Then I revised with him the proper procedure for the job and reviewed the chances of rejection. I asked him to start a new piece and call me to the machine while setting and before starting its machining. While he was returning, from his facial expression and body language I could make out the new realisation of his duty as a supervising engineer. In fact I also felt a lacking on my part that I did not train him much earlier with respect to this fine tuning of supervision.

But something more was in the store. While he was returning, as a vain and casual activity, I opened and closed the drawer of my table. Something struck my attention and I hurriedly opened the drawer and lo! To my pleasant surprise another blank of the punch was waiting for me to pick up. We keep such blanks ready for a family of punches in common so that with some fine operations the specific punch is ready! I almost yelled at Satish; he looked back in panic. I explained him the work. Both of us stood near the machine and got the finish punch ready. All is well that end well.

Such work places where standard routine work is not going on but every day some non-standard new type of work is there, this sort of experience is very common. Tool room, research & development shops, pattern shops and job work type set ups are some examples. Proper way is a) thorough discussion of the work with respect to drawings etc, b) discussion of pitfalls and probable errors, including the limitations of the particular machine and tooling, c) physically checking at every stage for control, and d) keep some safety options available…like extra blanks etc.

Narayan Joglekar is the ex-Principal and General Manager, Fr. Agnel Polytechnic Complex, Vashi. He has 25 years of shop floor management experience in companies like Mafatlal Engineering Industries and Dagger Forst Tools Ltd. and is currently working as Consultant in management and multi-skill training. He can be reached on njjoglekar@yahoo.com