Scrap reduction by using total quality management tools

A case study was carried out in one of the leading Indian industries manufacturing pre-stressed concrete steel strands (PC wire). It has major applications in bridges and construction industry. During study, lot of scrap was observed. Reasons for scrap was found out by using total quality management tools (TQM). Such as brainstorming, cause & effect diagram and pareto analysis. Main reasons were left over rings, non-conformity, chheda and weld/wire breakage. In the present study, scraps due to left over rings were reduced gradually by taking suitable action.