Mc Meeting May

Quality Assurance Wiring Harness Division  Top Defect Contributors and their Ranks  Thirteen months Trend Section Wise  Major Defect Areas (Internal)  Counter measures for Internal Defects  Customer Complaints Trend  Customer Defect Sigma This Time Special:  Cutting & Crimping Defects in PPM & New Targets  Honda Target Monitoring 07-08 & 08-09  Six Sigma Project in Implement Phase

Internal Defect Reduction Measures Taken to reduce the Internal Defects will be shared in this presentation.

Top Five Internal Defects Trend 2627

Circuit crossed ,open, missing, loose, Short

2449

1728 1190

1089

1045

Apr

May

June

2 2059

1853

1588

Aug

Sep

Oct

Nov

Dec-08

Jan-09

2733

Taping short / Excess / Loose/Miss

Clip/Clamps/Grt. Direction/Position wrong/excess/not cut

2797

2653

2686

1935 568 Apr

1121 May

1769

922

June

July

Aug

Sep

Oct

Nov

1434

238 Apr

May

1249

June

1552

Dec-08

July

1091

Aug

Feb-09

Mar-09

1

2 1541

1395 Jan-09

2187 278

1796

1188

919 July

Feb-09

Mar-09

Sep

729 Oct

Nov

291 Dec-08

5 545

Jan-09

Apr-09

3 988

Apr-09

3 1078

721

1

1

Feb-09

Mar-09

4 580 Apr-09

Top Internal Defects Trend Month Wise Def ec t Tr end & Rank Connector Lock Open/Others (Pvc Damage Cover Crimping)

1747

4 1332 730

Apr

May

June

493

608

July

Aug

Tube (V.T/V.S,Cot,Seal,fuse, foam,soldering, sleeve, fuse) missing/NG

1139

Sep

Oct

900

1320

Nov

215 Dec-08

Jan-09

Feb-09

4

Apr-09

3 5

1039

577

Mar-09

641

1023 381

404 Apr

May

262 June

July

Aug

Sep

Oct

Nov

178 Dec-08

Jan-09

Feb-09

Mar-09

Apr-09

2

1254

Insulator too short/Wong Cutting Length

292 Apr

May

June

July

Aug

Sep

Oct

Nov

Dec-08

Jan-09

Feb-09

Mar-09

Apr-09

Internal Defects Trend: Cutting Cutting PPM Trend 500.0

1400 1200

400.0

1000

300.0

800 600

Target PPM = 73

400

200.0 100.0

200

0.0

0 Apr-08 May-08 Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09 Crimping

PPM

Internal Defects Trend: Crimping Crimping PPM Trend 1600

400.0

1400

350.0

1200

300.0

1000

Target PPM = 118

250.0

800

200.0

600

150.0

400

100.0

200

50.0

0

0.0 Apr-08 May- Jun-08 Jul-08 Aug- Sep- Oct-08 Nov-08 Dec- Jan-09 Feb-09Mar-09 Apr-09 08 08 08 08

Crimping PPM

Internal Defects Trend: ECT ECT Trend: Defects and DPU 6000

0.14

5000

0.12 0.1

4000

Target = 0.055

3000

0.08 0.06

2000

0.04

1000

0.02

0

0 Apr-08 May- Jun-08 Jul-08 Aug08 08

Sep- Oct-08 Nov-08 Dec- Jan-09 Feb-09 Mar-09 Apr-09 08 08 ECT

DPU

Internal Defects Trend: FVI FVI Trend: Defects and DPU 7000

0.16

6000

0.14 0.12

5000

Target = 0.075

4000

0.1 0.08

3000

0.06

2000

0.04

1000

0.02

0

0 Apr-08 May- Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09 08 FVI DEF

DPU

April 2009 & Previous Two Months 74.0 55.6 343

29.2

310

216

169

136

100.0 90.0 80.0 70.0 60.0 50.0 40.0 30.0 20.0 10.0 0.0

(Corolla)453

Taping short / Excess / Loose/M iss 20%

100.0 88.4

(Corolla)454

Clip/Clamps/Grt. Direction/P ositi on wrong/excess/n ot cutt 12%

APR-09 (WORST FIVE)

(Land Rover)507

Tube (V.T/V.S,Cot,Se al,fuse,foam,sol dering, sleeve, fuse) missing/NG 8%

1200 1100 1000 900 800 700 600 500 400 300 200 100 0

(Corolla)464

Insulator too long/Wire Stands 25%

APR-09

(Corolla)468

Circuit (crossed/open/ missing/loose/S hort) 35%

Stage Wise Defect Trend DPU=0.1543

FEB-09 3376

DPU=0.1216

DPU=0.1136

MAR-09 2851

2962

1257 622

639 56

274

23 Crimp

ECT

APR-09 2149

2026

Cut

2793

FVI

Cut

Crimp

ECT

FVI

Cut

Crimp

ECT

FVI

Top Defects: April 2009 Circuit (crossed/open/ missing/loose/S hort) 35%

Tube (V.T/V.S,Cot,Se al,fuse,foam,sol dering, sleeve, fuse) missing/NG 8%

APR-09

Clip/Clamps/Grt. Direction/P ositi on wrong/excess/n ot cutt 12%

Insulator too long/Wire Stands 25%

Taping short / Excess / Loose/M iss 20%

Counter measures for Internal Defects

Daily Gemba Activity Daily Report is discussed. The Areas with higher defect rates are highlighted. Line leaders are given the tip for effective Corrective Actions.

Daily Gemba Activity Daily Defects are discussed with all line leaders to minimize the daily defects

Daily Gemba Activity

Daily Trends are monitored on two different boards.

Minimize the Foam Defects

Paper Sleeves (Recycle) being used to protect the foam from transportation defects

Wrong Clip Problem

Clip Pictures posted to ensure the Correct clip is used.

Clip Position/Direction Wrong Causes

Counter Measure

Clip loose, changes its direction and position during handling

workers trained to use standard torques for tightening Clips/ Quality Alert Issued

• Clips in tolerance but FVI worker not aware

Tolerances on Clip marked on master sample

Detailed RCCA of this defect attached with the mail

Evidence

Quality Alert on all Stations

Training of all team members on drawing and view understanding

Color coding provided on all boards to avoid wrong insertion.

Taping Loose/Missing/Excess/short Training on right method of taping conducted in March and April 09

QA and Prod staff group discussion to build a consensus on taping defects

Clip Missing Causes

Operator Missed the Clips (New Product understanding problems)

Counter Measure Training Provided. Clips provided in packets at Final Assembly in exact quantities. Number of Clips in packet is equal to the required number of clips in harness. Pictures of each Clip posted on all boards.

Evidence

Clip requirement along with direction mentioned on all Boards

Taping Missing/Excess/short Causes No Poke-yoke provided. Mostly on areas where Taping is required between the wires as no Clamps are installed for indicating taping length Variability in Operators

Counter Measure Use of stoppers on assembly board for indicating taping length on all such locations

Team member with their responsibilities including skill sets have been properly defined for all set of 2PS harnesses

Evidence

Taping Boundary clamps have been introduced wherever applicable to control the Short and excess taping.

Taping Loose Causes

Counter Measure

• Excess Handling / Excess Product traveling distance

Changes in Layout ECT and FVI boards placed next to conveyors (Honda Boards and Conveyors)

• Long waiting time due to shortages (specific for 2PS R Cabin Hood wire). •Operators have difficulty with the new product

Operators have been re-trained to ensure No loose taping.

Evidence

COT Damage Causes

Counter Measure

• Excess tightening

Operators retrained. Clip tightening torque on COT defined Instructions posted at each station.

of in order to fix the clips Improper Torque employed

Evidence

Torque standards for Tyton Guns posted every where. All JTMs retrained.

Connector Damage/ Urethane Foam Damage Causes

Counter Measure

• Excess Handling

Modifications in handling method trolleys now used instead of shoppers

• Urethane foam is a delicate part and can easily be damaged because of environment or during handling

Paper covers applied on urethane foams

Evidence

Additional Pictures for the Corrective measures.

Additional Pictures for the Corrective measures.

Wrong Insertion • Location Wise Data Collection for Critical Assemblies

Root Cause : Same Color same gage wires inserted on same station

Subassembly drawings will be revised to divide such Drawings in two or more than two drawings: DM Production is working on the project.

Quality Alerts Posted on every single Sub Assembly Station

Wrong Insertion Tags have been introduced to clearly identify First Off Inspection at Sub Assembly

• After first off inspection the sub assembly is tagged and acts as sample. • Tags also ensure that no station is left for First off inspection

Taping Loose/Missing/Excess/short

Location No marked on Master sample for Critical Assemblies. Location wise data collection at FVI starts from May

Clips Position/Direction wrong Clip requirement along with direction mentioned on all Boards

LOCK OPEN Lock Open Issues highlighted in the daily GEMBA meeting and the importance of Zero defects discussed with all line leaders.

Quality Alerts posted showing OK and NG condition of Lock

WRONG CUTTING LENGTH • Appeared for the first time due to wrong cutting of whole bunch on KOMAX

Capability Analysis for KOMAX shows machine can cut the wires in a range of 1mm. Operator feeding values too close to LCL.

Customer Care

Date Reported

15 April 2009: WIRE, INSTRUMENT PANEL (IMV) Wrong Sequence of Connector

History NIL

Failure Mode reported Failure mode Position of two similar color determined connectors get interchanged by Thal Immediate Corrective Action

Stock checked, Included in PDI check point

Done On

15-April-09

Permanent Corrective Action

Master Sample Changed, Crimped scrap wires of similar colors inserted in similar order in connectors of sample

Done On

15-April-09

Ok Sequence of Connector

Wrong Sequence of Connector

Date Reported

28 April 2009: WIRE, ENGINE HARNESS CIVIC

WRONG MODEL ENGINE HARN Failure Mode DISPATCH reported

History NIL 2ZH

Failure mode ENGINE HARNESS OF 2YH MODEL determined DISPATCHED INSTEAD OF 2ZH by Thal Immediate Corrective Action

Stock checked at HACPL and THAL

Done On

28-April-09

Permanent Corrective Action

For visual identification of harness The color of label fixing for 2YH model is changed to Green

Done On

30-April-09

2YH

Difference in 2ZH and 2YH model is P-OIL Branch delete in 2ZH

Customer Reported Defects & Sigma Level CUSTOMER COMPLAINTS CUSTOMER DEFECTS Parts Rejected HARNESSES SUPPLIED DEFECT RATIO DEFECTS IN M PARTS DPMO OPPORTUNITIES PROCESS SIGMA Honda Ranking

Nov-08 Dec-08 Jan-09 1 1 2 1 1 4 1 1 4 47305 30888 42078 2.1139E-05 3.2375E-05 9.5062E-05 21.1394144 32.3750324 95.0615524 0.70464715 1.07916775 3.16871841 1.419150E+06

6.32 Best

Feb-09 Mar-09 Apr-09 0 2 2 0 3 2 0 3 1 39525 52123 56932 0 5.7556E-05 3.513E-05 0 57.5561652 17.5648142 0 1.91853884 1.17098761

9.26640E+05 1.262340E+06 1.185750E+06 1.563690E+06 1.707960E+06

6.24 6.01 Best Best Middle

8 Best

6.12 Best

PPM = 18

6.22 Best

HONDA PPM Target for Year 07-08 Par t Supply

A p r' 0 7 ~ M ar' 0 8

A pr-08

Total Supply

264304

16620

OK Parts

264280

16620

24

0

Repair/Rework(In-house& HACP L)

Par t s Reject ion at HA CPL (PPM) Ta rge t : 1st Ha lf 113 Ta rge t : 2nd Ha lf 85

300

150 Actual PPM: 96

200

150

1

100 50

100

0

0 Ac tual - 84 Ki

0

Apr-0

HONDA PPM 08-09 AND NEW TARGET Par t Supply Total Supply OK Parts

A pr-09

A p r' 0 8 ~ Feb ' 0 9 o n A ve rag e Basis

Repair/Rework(In-house& HACP L)

19020 19020

Actual PPM: 78

0

Par t s Reject ion at HA CPL (PPM)

300

75

Ta rge t : 50 PPM Old Target: 150

200

50

150

50

25

100

0

0 Ac tual - 85 Ki

0

Apr-09

Honda Rating for the Month

Customer Complaints – 13 Months Data (APRIL 2008 – APRIL 2009) COMPLAINTS CUSTOMOR

HACPL

1

20

IMC

1

10

SIGMA

0

0

HINO

0

0

PSMC

0

0

DYMCL

0

0

TOTAL

0

30

DEFECTS

WH CUSTOMER COMPLAINTS (Apr 08- Apr 09)

MTD YTD

04-08 04-09

0

2

12 10 8 6 4 2 0 Apr- May- Jun- Jul- Aug- Sep- OctNov- DecJan- Feb- Mar- AprHACPL IMC 08 08 08 08 08 08 08 08 08 09 09 09 09

Customer Complaints & Sigma Level Customer Defects & Sigma Level (Apr 08 - Apr 09)

∞

10

9

8

9 8

8

6.12

7

6.22 7 6

6

Sigma Level = 6.22 Target Sigma = 6.0

5 4

5 4

3

3

2

2

1

1

0

0 Apr-08 May- Jun-08 Jul-08 Aug-08 Sep- Oct-08 Nov-08 Dec- Jan-09 Feb-09 Mar-09 Apr-09 08 08 08 CUSTOMER DEFECTS

PROCESS SIGMA

Customer Complaints & PPM Customer PPM Apr 08- Apr 09 10 9 8 7 6 5 4 3 2 1 0

228

250

131 64

143

150

94

95

51 21

0 Apr-08 May-08 Jun-08 CUSTOMER COMPLAINTS

Jul-08

32

58

DEFECTS IN M PARTS

18

100 50

0

Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09

Parts Rejected

200

Target PPM = 69

0 Apr-09

SIX SIGMA PROJECT Project Scope:

Cost Saving by reducing wire Lengths in 242L room main Assemblies

Project Details:  Length

of 49 wires of 242L room main was found excess. A sample was submitted to IMC where it was installed in vehicle and the “Fit & Function” was found OK.

Expected Saving:

Saving per Harness : Rs.136/Harness Monthly Saving (Xli) : Pak Rupees 204,622 Monthly saving (all models): Pak Rupees 409,244

Yearly saving : Pak Rupees 4,910,932 4.9 Million yearly Savings expected

THANK YOU