Concept Diagram - Figure of ‘8’

10
Carry out
5
revision in
4 Analysis
inspection
Carry out 4 standards
M analysis + 6
Apply PM Implement
analysis for Kaizens 9
chronic Prepare QM
problems matrix
QUALITY QUALITY
3 KAIZEN MAINTENANCE
Ensure
should be
value of 4M
condition 1
2 Find 7 8
Find Defects & Setting Establish
process & defect conditions standard
machines modes for Q factors values
where &Q
defect components
occurs

Chapter No. 7 QM Pillar A.R. Ref. Page- 170 Slide 356 of 592
 Pillar Approach

Chapter No. 7 QM Pillar A.R. Ref. Page- 171 Slide 357 of 592
 Sources of External Customer
complaints

External
Customer
Complaints

Vehicle
Field Plants

M&M M&M MVML M&M

Nasik Haridwar Chakan Zaheerabad

Chapter No. 7 QM Pillar A.R. Ref. Page- 171 Slide 358 of 592
 Case Study – Vehicle Plant Complaint

Step 1: Confirmation of actual Condition

Vehicle Plant Complaint Engine Model Wise & Phenomena wise in incidences F14
Vehicle Plant Complaint -Engine Model wise -F14

NEF, 12

Mustang, 14 mHawk, 44

LCCR Scorpio,
29

LCCR Bolero, 35

Chapter No. 7 QM Pillar A.R. Ref. Page- 172 Slide 359 of 592
 Case Study – Vehicle Plant Complaint
Step 1: Confirmation of actual Condition

Defect: Diesel leakage from Cracked overflow pipe.

Defect mode: Overflow pipe is Cracked at `T’ joint

Overflow Pipe : Pipe which flows fuel back flow from injector after
injection is over Overflow Pipe
T Joint

Injectors

BAD - Overflow pipe broken GOOD - Overflow pipe intact

Chapter No. 7 QM Pillar A.R. Ref. Page- 173 Slide 360 of 592
 Case Study – Vehicle Plant Complaint
Step 2: Investigation of processes in which defect occur

QA Matrix

PU / Shop / Dept. : mHawk Date: 10 Apr

Plant : Igatpuri Cell / Circle : mHawk circle
Assembly & testing 14

Legend Generation - 'G' Detection - 'D'

Detected at (e.g. Warranty,

Generated at ANOVA-C, RFI, CAI, FAI, Buy-off,

(Severity X Occurrence)
User Plant, ICC, Global Demerit)

No. of incidences
Concerns Stage / M/C Numbers

Criticality
↓ Process Description →

Severity
Cam cover Harness clip

Overflow Pipe Fitment

Phase sensor Fitment
Water housing gasket

Global demerit audit

Sr. No.

Alternator assly

Engine Testing

Vehicle Plant
Dock Audit
Defect Mode / fitment

fitment

Buy-off
LBLT
ACT

Field
Part Name &
Defect
Location
Phenomenon
(e.g. Door LH
(e.g. Paint
Side)
Rundown)

Overflow
01 Cracked G D 9 6 54
Pipe
02 Cam cover G D 7 7 49
Harness clip Loose
03 Water inlet G D 7 6 42
housing gasket Twist
04 Phase sensor leakage G D 7 5 35

Chapter No. 7 QM Pillar A.R. Ref. Page- 173 Slide 361 of 592
 Case Study – Vehicle Plant Complaint
Step 3: Survey & analysis of 4 M conditions
Home Work Point No: QM- 3
Focus on 4 M analysis for each & every stage / machine.
Sugiura San

4M Parameter Standards Actual OK/Not ok Status

MAN Skill level Level 3 minimum Level 3 OK √

1 Checking of overflow pipe Fitment 100% Visual Checking Not checked Not OK

MACHINE Pressing dollys level At one level At one level OK √

2 Pressing Dolly Physical condition Free from Dent/damages Worn out Not OK
Pressure Cylinder pressure 5 bar 5 bar OK √

Overflow pipe connector fitment Straight Fitment Cross Fitment Not OK

3
Method to engine
Handling of pipe Properly roll down & Properly roll down & OK √
placed in kitting place placed in kitting place

Overflow pipe diameter 7±0.5 7.2 OK √

T Joint Height & Width 17.5±0.5x33±0.4 17.3x33.02 OK √
Material Overflow pipe Physical condition Free from dent/damages No damage OK √

Overflow pipe connector physical Free from dent/damages No damage OK √

condition

Chapter No. 7 QM Pillar A.R. Ref. Page- 174 Slide 362 of 592
 Case Study – Vehicle Plant Complaint
Step 4: Problem counter measure study & restoration
Complaint Parameters Why 1 Why 2 Root cause Action Status

1 Cracked Visual Check Visual Touch & feel

Overflow pipe Check check
not able to
detect
Overflow 2 Dolly Worn Less Wear Less Wear High Wear
pipe out Resistance Resistance Resistance
breakage property property property
from T Joint Cross Fitment Pressing Dolly Pressing Pressing Common
3
of Overflow position & dolly has reference
Pipe injector hole dolly has isolated
position isolated reference
mismatch. reference

Chapter No. 7 QM Pillar A.R. Ref. Page- 174 Slide 363 of 592
 Case Study – Vehicle Plant Complaint
Step 4: Problem counter measure study & restoration
Kaizen 1
Home Work Point No: QM- 1
Use methodology of CAN NOT FLOW (Inspection Side) & CAN NOT MAKE (Cause Side).
Sugiura San

Before After
Touch & feel check with the
Visual Check
help of hand

Can not
Flow

Chapter No. 7 QM Pillar A.R. Ref. Page- Nil Slide 364 of 592
 Case Study – Vehicle Plant Complaint
Step 4: Problem counter measure study & restoration
Kaizen 2
Before After
Pressing Dolly of Softer material Pressing Dolly of Hard Material
leads to wear

Teflon Material Aluminum Material

Can not
Make

Chapter No. 7 QM Pillar A.R. Ref. Page- 176 Slide 10 of 592

 Case Study – Vehicle Plant Complaint
Step 4: Problem counter measure study & restoration
Kaizen 3
Before After
Pressing dolly & Overflow pipe New Fixture Plate with Pressing dolly
Nipple axis misalignment made
Patent
Registered

Can not
Make

Chapter No. 7 QM Pillar A.R. Ref. Page- 176 Slide 11 of 592

 Case Study – Vehicle Plant Complaint
Step 9 : Determination of Standard Values for
Inspection
As this defect is Sporadic, Hence from step 4 going to step 9 i.e. to sustain the gains, as
prepared Quality Component.
Q component
Equipment Block To Which Inspection Standard Method of Inspection What
diagram Pillar Item Value checking frequency defect will
Hand come
over - JH
/ PM
TM Fixture Free from Visual Once in a Cross
Condition Damages/ Month Fitment of
Worn out Overflow
Pipe
TM Spring Spring Functional Once in a Cross
condition function verificatio month Fitment of
n Overflow
Pipe
TM Pressing Dolly Wear Out Visual Once in a Cross
condition month Fitment of
Overflow
Pipe
TM Locating Pin No Visual Once in a Cross
condition Bend/Dama Month Fitment of
ge Overflow
Pipe

Chapter No. 7 QM Pillar A.R. Ref. Page- 176 Slide 12 of 592

 Case Study – Vehicle Plant Complaint
Step 9 : Determination of Standard Values for
Inspection
QM matrix for Sustenance :
Phenomena 4M Control Abnormality Cause of criteria Check Frequency Responsibil
condition item abnormality Method ity

Overflow Man Overflow Cracked Cross Straight Visual 100% Workmen

pipe pipe Fitment Fitment Inspection

breakage fitment

Chapter No. 7 QM Pillar A.R. Ref. Page- 177 Slide 13 of 592

 Case Study
Step 10 - Field
: Revision complaint
of Standards
Snap shot
Standard Before After Remark
of Standard
SOP before
SOP Updated as per action
SOP action Revised
implemented
implementation
Fixture New
No Drawing Fixture Drawing updated
Drawing
CLITA Before action
CLITA point added Revised
Sheet implementation

MP sheet given to DM New

MP Sheet No Sheet
Pillar
OPL before
Checking of Fitment New
OPL action
implementation
Fixture Sheet before
Check point added for Revised
inspection action
Fixture inspection
sheet implementation

Chapter No. 7 QM Pillar A.R. Ref. Page- 178 Slide 14 of 592

 Case Result
Study – Vehicle
of HLA Noise
Plant
Complaint Better

Defect
Eliminated

Chapter No. 7 QM Pillar A.R. Ref. Page- 178 Slide 15 of 592

 Monitoring of Activities
complaints reduction
for
External Customer Home Work Point No: QM- 1
Use methodology of CAN NOT FLOW (Inspection Side) & CAN NOT MAKE (Cause Side).
Sugiura San

Kaizen done in F15

Can Not Flow Can Not Make

36 33

Chapter No. 7 QM Pillar A.R. Ref. Page- 179 Slide 16 of 592

 Sources of External Customer
complaint
External
customer
complaints

Vehicle
Field plants

M&M MVML M&M

M & M Nasik Haridwar Chakan Zaheerabad

Chapter No. 7 QM Pillar A.R. Ref. Page- Nil Slide 17 of 592

 Case study of Vehicle plant complaint
Theme : To eliminate the complaint of noise on mHawk engine from Field

Will be shown in
Schedule ‘B’

Chapter No. 7 QM Pillar A.R. Ref. Page- Nil Slide 18 of 592

 Sources of Internal Customer
Complaints

Internal
Customer
Complaint

Engine Assembly
Global Demerit Engine Testing defect due to In
Dock Audit Audit Rework house Machined
Parts

Chapter No. 7 QM Pillar A.R. Ref. Page- 179 Slide 374 of 592
 Inciden

10
15
20

0
5
ces

Chapter No. 7
Cylinder Head

5
mounting bolt
hole shifted
Head Gasket

3
leakage
due to
chips
Leakage through

3
Head & Cam
cover Joint face
Head Gasket

2
leakage due to

QM Pillar
scratch on joint
Coordinate
face off of

1
tooling hole on
OP40 machine
Cylinder Head intake

1
side 3rd HLA
bore oversize

D e fe c ts
Cylinder Head
1
Exhaust side
M10 tapping
4thdepth less
injector
1

compression
leakage in
engine at ACT
1

Engine Heavy
smoke
Machining Defect line wise and Phenomena wise incidences F13

P a r e t o A n a ly s is o f C y lin d e r H e a d d e f e c t s - F 1 3

Cylindr Head
1

joint face
damaged
A.R. Ref. Page- 180
1

OP 10
Shift
Case Study – Internal Defect Elimination
Step 1: Confirmation of actual Condition

OP 50 without
dowel
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%

Slide 375 of 592

 Case Study - Internal Defect Elimination
Step 2: Investigation of processes in which defect occur
QA Matrix
Cell / Circle : Head
Plant : Igatpuri PU / Shop / Dept. : Machine Shop Date: Apr-13
line

Lege Generation -
nd 'G'
Detection - 'D'

Detected at (e.g.
Warranty,
ANOVA-C, RFI,
Generated at F13
CAI, FAI, Buy-off,
User Plant, ICC,

(Severity X Occurrence)
Global Demerit)

No. of incidences
Stage / M/C Numbers →

Criticality
Severity
Concerns Process description
Sr.

guide pressing machine

Valve leak test machine

Final washing machine

No.

Water Jacket leak test

Final Inspection stage

Intermediate washing

Welch Plug pressing

Camcover torqueing
Valve seat and valve

ASRS loading stage

OP20/30 machining

OP20/30 machining

OP20/30 machining

OP20/30 machining

OP40 machining

OP50 machining
Op10 machining

machine 2
Part Name &

machine

machine
process

process

process

process
process
process

process

Testing
stage

CMM

Assly

Total
Field
Location Defect Mode / Defect Phenomenon
(e.g. Door LH (e.g. Paint Rundown)
Side)

Co-ordinate off of Tooling

19 Head G/D 1 8 1 8
Hole on Op40 machine

Cylinder head is difficult to

20 Head G D 5 9 5 45
assemble on the engine block

Head Gasket leak due to

21 Head G D D 3 8 4 32
dent mark in Cylinder Head

Rejection of cylinder head

22 Head due to wrong loading of G/D 2 8 2 16
component on OP 30 fixture

Chapter No. 7 QM Pillar A.R. Ref. Page- 181 Slide 376 of 592
 Case Study - Internal Defect Elimination
Step 3 : Survey & analysis of 4 M conditions for
operation shift
4M Parameter Standards Actual OK/Not ok Status
MAN Skill level Level 3 minimum Level 3 OK √

SOP adherence 100% adherence 100% OK √

adherence
MACHINE Permanent clamping 70 ± 5 Kg/ cm2. 72 bar OK √
Pressure (70 bar)
Condition of Locating pins Not Bent, No Damage, No damage OK √
and Rest Pads. Teflon cap Present. observed
Hydraulic Leakage No Hydraulic Leakage on No leakage OK √
and around fixture. observed
Machine Door, Shower Door Clean, all Shower Clean and All OK √
Nozzle position Nozzle Working and Nozzles in
orientation Correct. working
condition
Spindle Through Inform 20-30 Bar Check on 23 bar OK √
Officer coolant Pressure Finishing tool
Coolant Concentration 8-10% 9% OK √

Coolant temperature 20-22°C 22°C OK √

Chapter No. 7 QM Pillar A.R. Ref. Page- 182 Slide 377 of 592
 Case Study - Internal Defect Elimination
Step 3 : Survey & analysis of 4 M conditions for
operation shift
4M Parameter Standards Actual OK/Not Status
ok
MATERIAL Height of joint face to 124.5±0.05 mm 124.530 MM OK √
top face
Flatness 0.1 Overall (0.03 / 0.03 OK √
100 x 100)
Surface finish Rz 10 3.4 Rz OK √
Tool / insert wear, As per tool history Tools found with OK √
damage card normal wear
pattern
Valve guide diameter Ø11.0 +0.018mm 11.014 mm OK √
Valve seat Diameter Ø30.2 +0.025mm 30.210 mm OK √

All operations completed As per control plan All operations are OK √

completed

Chapter No. 7 QM Pillar A.R. Ref. Page- 182 Slide 23 of 592

 Case Study - Internal Defect Elimination
Step 3 : Survey & analysis of 4 M conditions for
operation shift
4M Parameter Standards Actual OK/Not Stat
ok us

METHOD Cleanliness of Rest Rest pads must be clean, no Found in clean conditions OK √
pads, Locating Pins,
Support Plate. damage and breakage to
locating pins
Tool length offset As per machine / zoller Found as per OK √
input data specifications for all tools

No tool breakage No tool breakage Tool found in OK condition OK √

Work offset As per defined pallet Pallet found interchanged Not OK

on machine with wrong

offsets loaded
Part NC program As per defined program NC program found same OK √
on both pallets as per
requirement

Chapter No. 7 QM Pillar A.R. Ref. Page- 182 Slide 24 of 592

 Step 4 : Problem
Casecounter measure
Study – Internal study
Defect & restoration
Elimination
Analyzed cause :
 Some times we have electrical power supply interruption.
 OP 40 - Machining setup 7 machine & 14 fixtures with each machine having
2 pallets
 During Power Supply interruption; Pallet of Machine used to get interchange
in the system memory,(Pallet A becomes B & Pallet B becomes A ) which
cause running of wrong program
Normal Condition Abnormal Condition
Required Actual Required Actual

A B
A A

P
B A
BRight palletB Wrong pallet
O
selection selection
Chapter No. 7 QM Pillar A.R. Ref. Page- Nil Slide 380 of 592
 Case Study - Internal Defect Elimination
Step 4 : Problem counter measure study &
restoration
Complaint Parameters Why 1 Why 2 Root cause Action Status

Mounting Work offset pallet No No Visual

bolt hole change interchange identification identificatio Identification
shifted on pallets n on pallets Pallets

pallet No difference No Differentiate

interchange between difference the Pallet
pallets between
pallets

pallet No pallet No pallet Pallet Check

interchange Check Check provision in
provision in provision in the Machine
machine machine

Chapter No. 7 QM Pillar A.R. Ref. Page- 183 Slide 26 of 592

 Case Study - Internal Defect Elimination
Step 4 : Problem counter measure study & restoration
Kaizen 1
Before After
No Identification Tool mark for Identification

Chapter No. 7 QM Pillar A.R. Ref. Page- 183 Slide 27 of 592

 Case Study - Internal Defect Elimination
Step 4 : Problem counter measure study & restoration
Kaizen 2
Before After
No Difference in Pallets Difference in Pallets by providing slots
at different Coordinates

FIXTURE FIXTURE FIXTURE FIXTURE

A B A B

No difference on pallet Differentiation done by providing

slots

Chapter No. 7 QM Pillar A.R. Ref. Page- 184 Slide 28 of 592

 Case Study - Internal Defect Elimination
Step 4 : Problem counter measure study & restoration
Kaizen 3
Before After
No Checking mechanism of pallet Checking of pallet with tool load &
before starting the Operation Interlocking mechanism

FIXTURE

A FIXTURE FIXTUR
FIXTUR
B E E

A B

Pallet Check in auto cycle with tool load

No Pallet Check in interlock monitoring and program interlock

Chapter No. 7 QM Pillar A.R. Ref. Page- 184 Slide 29 of 592

 Case Study – Vehicle Plant Complaint
Step 9 : Determination of Standard Values for
Inspection
As this defect is Sporadic, Hence from step 4 going to step 9 i.e. to sustain the gains, as
prepared Quality Component.
Q component
Equipment Block To Which Inspection Standard Method of Inspection What
diagram Pillar Item Value checking frequency defect will
Hand come
over - JH
/ PM
PM Functioning Interlock Simulatio Once in a Mounting
of Logic working n month bolt hole
shift
PM Functioning Wire Physical Once in a Mounting
of logic Connectio checking month bolt hole
n shift
TM Pallet slot As per Coordina Once in a Mounting
dimension Drawing te Six month bolt hole
Measurin shift
g
Machine
TM Tool load damage Visual Once in a Mounting
checking month bolt hole
plate shift

Chapter No. 7 QM Pillar A.R. Ref. Page- 185 Slide 30 of 592

 Case Study – Vehicle Plant Complaint
Step 9 : Determination of Standard Values for
Inspection
QM matrix for Sustenance
Phenomena 4M Control Abnormality Cause of criteria Check Frequency Responsibil
condition item abnormality Method ity

Offset Method No Pallet Pallet No Identifica Simulation Once in a Process

change Intercha Interchang identification tion & month engineer

nge e & Interlock interlock
working

Chapter No. 7 QM Pillar A.R. Ref. Page- 185 Slide 31 of 592

 Case Study - Internal Defect
Step 10 : Revision of Standards
Standard Before Elimination
After Remark
Snap shot
of Standard
SOP before action SOP Updated as per action
SOP Revised
implementation implemented

Fixture Slot & tool mark for

No slot & Tool Mark Revised
Drawings identification

Machine
No interlock Interlock Revised
Program

OPL Nil Change in logic New

PFMEA,CP No failure mode Failure Mode Revised

Fixture
Check point added on Load
Inspection No checkpoints Revised
plate condition
Sheet
Chapter No. 7 QM Pillar A.R. Ref. Page- 186 Slide 32 of 592
 Case Result
Study - Internal
of operation shift
Defect
Elimination Better

Chapter No. 7 QM Pillar A.R. Ref. Page- 186 Slide 33 of 592

 Results Status Table

Chapter No. 7 QM Pillar A.R. Ref. Page- 187 Slide 34 of 592

 Results Graph KPI

Chapter No. 7 QM Pillar A.R. Ref. Page- 188 Slide 35 of 592

 Results Graph KPI

Chapter No. 7 QM Pillar A.R. Ref. Page- 188 Slide 36 of 592

 Results Graph KPI
Home Work Point No: QM- 2
‘Direct Pass Ratio’ is added in KPI in terms of ‘First Run Capability’.
Sugiura San

Chapter No. 7 QM Pillar A.R. Ref. Page- 188 Slide 37 of 592

 Results Graph KAI

Chapter No. 7 QM Pillar A.R. Ref. Page- 188 & 189 Slide 393 of 592
 Results Graph KAI

Chapter No. 7 QM Pillar A.R. Ref. Page- 189 Slide 394 of 592
 Intangible Benefits

 Mindset changed from Reducing defect to “Zero Defect stages & Zero
Defect Parts”.

 New defect solving tool learnt like P.M. Analysis, Q.A. Matrix.

 Q – Component helps in Sustaining results

 Boundary less working approach for achieving Zero Defects

Chapter No. 7 QM Pillar A.R. Ref. Page- Nil Slide 395 of 592
 Future Plan
Parameter UOM Target Actual Status Action Plan Target Date
(Till Nov 14)
Reduction Field complaints 0 0.06 Increase no 31 Mar 15
in internal – (R/1000) of Zero
customer Vehicle plant 0 0.38 Defect
complaint complaints – machine &
(R/1000) assembly
Reduction Dock audit – 0 0.517
stages to
in internal (R/1000)
customer 100 % &
Engine testing 0 312
complaint rework - Carryout PM
(PPM) Analysis &
Engine assembly 0 82 Design Of
rework due to in Experiment
house machined projects
parts – (PPM)
First Run 100 98.09
Capability (%)

Chapter No. 7 QM Pillar A.R. Ref. Page- 190 Slide 396 of 592