Storm,sundaram Clayton

QC STORY

STORM QCC WELCOMES YOU ALL FOR OUR SECOND PROJECT PRESENTATION STORM QCC

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STORM QCC

INTRODUCTION

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INTRODUCTION

Milestones • 1968 Started as captive unit with aluminium Gravity Die castings - GDC • 1983 Started manufacturing aluminium Pressure Die castings -PDC. • 1987 Awarded for best industrial relations by Government of Tamilnadu. •1993 Started Die design using CAD •2000 Certified for QS - 9000. •2000 Installed alloying plant •2000 Global supply commenced. •2001 Best supplier award from Hyundai Motor India limited. •2001 Started collaborative product. development with MNC customer. STORM QCC

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INTRODUCTION

Sundaram Clayton QCC Projects trend - DCD

100% Participation 700

581

600

482 387

400

200 100

148

196

241

84 95 99 62 60 82 48 45 42 236 24 22 24 106

100

100

100

100

100

100

99-00

00-01 2001-02 2002-03 2003-04 20042005

20052006

80

303

300

100 100

% of participation

No of projects

500

75

65

50

25

0 95-96

96-97

97-98

98-99

99-00

00-01

Year

STORM QCC

200102

200203

200304

2004- '05-Jan 2005 06

0 97-98

98-99

Year

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INTRODUCTION

SCL - Die Casting Division Customers Export

Domestic  

TVS Motor Company Sundaram-Clayton





(Brakes Division)        

Hyundai Motors Ford Visteon Honda Volvo Tata Cummins Tata Holset Sona Koyo Steering Systems STORM QCC

Cummins Group   

Cummins , USA Komatsu Cummins - Japan Fleetguard, USA Holset, USA

Ford - Brazil, Mexico and South Africa Under negotiation  Volvo, Sweden  Mack, USA  Renault, USA 

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INTRODUCTION

STORM QUALITY CIRCLE STARTED MONTH& YEAR

: DECEMBER - 2004

NATURE OF WORKING AREA

: PLANT MAINTENANCE

LEADER MEMBERS

: D.SAMUEL RAJAN : S.VIJAYAN : S.SHANMUGAPRABU : N.SUBRAMANIAN : S.SILAMBARASAN : S.SHAHUL HAMEED : P.NETHAJI.

FACILITATOR

MEETING DAY STORM QCC

:EVERY WEDNESDAY AT 3.45 PM TO 4.45 PM DEPT CODE PRO. CODE PAGE NO

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1.0 PROBLEM

HIGH BREAKDOWN IN FILTER MODULE CELL (196Hrs & 32 Freq. )

Apr’05 - Jun’05 200

CELLWISE BD HOURS

196

82

STORM QCC

Visteon

Gear Hsg

Honda

Ford oilpan

18 12 8 4 MY 4.5

51 36 31 25

Honda Case Chain

0

Filter module

50

CLOC

62

Lub module

100

ISXHead FF

BD Hrs

150

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Cell

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1.2 IMPORTANCE OF PROBLEM

• Machine breakdown leads to delivery failure • Delivery failure leads to Business loss • TPM calls zero breakdown.

10700 10680 10660 10640 10620 10600 10580 10560 10540 10520 10500

60 56 52 48 44 40

BD HOURS

CELL OUTPUT

• The Breakdown of a machine affects the entire cell output.

Cell output

M/C Break down

Apr'05 May'05 Jun'05

MONTH

STORM QCC

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OBJECTIVES

Policy Deployment Objectives-X-matrix(DCD Machining Cell): DieCastingDivision-PMDMachining

President TO :

STORM QCC

Head-DCDPMDM/ing

1 2 3 4 5 6

75% 10%

80%

1A5 Maintain essential spare stock

1A5 Stengthen weekly PM

100%

95% 1A4 Daily Monitoring of 'B' & 'C' rank M/c 50% B/d

75% 20% 1A3 Maintain Stock of critical spares

95%

100%

TO 0.30 140 150 4hrs 60days 8%

1A2 Daily PDCA of rank 'A' machines 80%

FROM 0.60 290 177.23 4.5hrs 80days 3%

1

2

MATRIXOFPOLICYFOR2005-2006

RESPONSIBILITY

F:\BPN\001\BPN rev. 0 dt 19.03.2005

3

OBJECTIVES Reduceoverall M/c B/D%(machineWise) Reduceoverall M/c B/DFrequency Reducerepair andmaintenancecost(lakhs) RedcuceMTTR ReduceMTBF ReduceEnegy consumption

1A1 Increase No. of PM checks

ACTIONPLAN

Head-DCDPMD Machining

1A1 1C1 1D1 1E1 1F1 1G1

DIRECTEDBY :

80%

TO

25.2 TO 25.8 FROM

FROM

31.4 26.5

%

%

PRESIDENT

Profitability

21

6.2 0.7 %

336

GUIDELINES

OBJECTIVE

Profit

1.9

Rs cr 256

Rs cr Increase sales and

0.5

10 24

1.4 %

% Casting

Machining

100

2 5 %

ppm 1800 Customer end

Reduce rejections

improve new product quality%

10

8

28

Increase new product sales Rs and cr

37

4.1Implementationof TPMcompany wide 3.3Buildcompeteneceincastingprocess 3.2StrengthenNPDprocess 3.1StandaardiselearningthroughSOP's guibelines andproject PDCA 2.3Implement pokeYokes 2.2Revisit dieandprocess design 2.1Establishprocess controls andadhere(measure:noof out of control processes) 1.6Improvecapital andemployeeproductivity by re-engineering,lowcost automationand outsourcing(measure:sales/employeeandsales of GFA) 1.5Implement wasteeliminationproject-yield,Melting,Energy,consumables 1.4Alternatesourcing 1.3Maximiseexport benefits andFTAbuyingfor aluminiumpurchase(Measure 1.2Pamp-upnewproducts ontime(meausure 1.1Retainmarket sharewithexistingcustomers (measure:

Marketing Operations - DCD Operations - Machining Purchase Quality assurance Engineering

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To Reduce BD% from 0.60 to 0.30

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TO

TO

OBJECTIVES

FROM

FROM

G U ID ELIN ES

PR ESID EN T

O BJEC TIVE

AC TIO NPLAN

H ead-D C DPM D M achining O BJEC T IVES 1A1 1B1 1C 1 1D 1 1E1 1F1 1G 1

R educeoverall M /cB/D% (m achineW ise) R educeoverall M /cB/D% (C ell W ise) R educeoverall M /cB/DFrequency R educerepair andm aintenancecost(lakhs) R edcuceM T TR R educeM T BF R educeEnegyconsum ption

STORM QCC

FR O M 0.60

TO 0.30

290 177.23 4.5hrs 80days 3%

140 150 4hrs 60days 8%

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1.3 Theme and Target

TARGET Break down percentage for Filter module Cell 2

1.6

1.58

1.53

Less than 0.25% by the

1

B/D %

month of Aug’05 0.25 0 Apr'05

May'05

Jun'05

Jul'05

Aug'05

Month STORM QCC

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BACKGROUND

CUSTOMER

: FLEET GUARD

PRODUCT NAME

: FUEL FILTER

HOUSING PART NUMBER

: 393588800

APPLICATION

: FILTER ASSEMBLY

DELIVERY

: FULLY MACHINED

MATERIAL

: ALUMINIUM - ADC12

COMPONENT COST : $ 15.35

:

CASTING TYPE

STORM QCC

: PRESSURE DIE CASTING

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1.4 SCHEDULE FOR IMPROVEMENT

GANTT CHART WEEK NO ACTIVITIES

RESP

DATA COLLECTION

TEAM

PROBLEM SELECTION

TEAM

ANALYSIS

TEAM

SOLUTION SELECTION

TEAM

IMPLEMENTATION

TEAM

OBSERVATION

TEAM

STANDARDISATION

TEAM

STORM QCC

14

15

16

17

18

19

20

PLAN

21

22

23

24

25

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2.0 OBSERVATION – COLLECT &ANALYSE DATA

DATA COLLECTION FOR CELL WISE B/D FREQ. & HOURS (FROM APR‘05 - JUN‘05) H our s 196.33 200 10 0

ISX Fwh

MY 4.5

Honda Case chain

Ford Oil pan

Honda Oil pan

Head FF

Lub Module

Cloc

Honda Case Chain

Filter Module

0

Gear Housing

Visteon Gear Housing Filter Module Honda Case Chain cloc Lube Module Head FF Honda Oilpan Ford Oilpan Honda Casechain MY 4.5-Holset ISX-Flywheel Hsg

Hours Frequency 7.24 3 17.76 6 196.33 32 25.47 6 35.57 8 50.79 14 61.89 5 31 4 4.17 1 23 6 12 5 82 17

Visteon

Cell

Fr equen c y

32

Frequency

40 20

STORM QCC

ISX Fwh

MY 4.5

Honda Case chain

Ford Oil pan

Honda Oil pan

Head FF

Lub Module

Cloc

Honda Case Chain

Filter Module

Gear Housing

Visteon

0

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2.0 OBSERVATION – COLLECT &ANALYSE DATA

PARETO ANALYSIS FOR FILTER MODULE BREAK DOWN DETAILS

Sno Machine 1 089407 2 033501 3 033502 4 033801 5 085839 6 089505 7 089506

Description B/D HRS % % WINNER XL 1.83 0.93 2 4 0 220 ACE LT 20C 9.5 4.84 21 08 00 1 6 2 8 8 .1 9 9 3 .2 5 9 8 .0 9 9 9 .0 2 1 0 0 1 0 0 ACE LT 20C 0 0 11 64 00 8 2 .5 LT-20CLASSIC 1.75 0.9 11 20 00 80 SPM 162 82.5 6 0 40 1 1 .1 7 1 0 9 .5 1 .8 3 1 .7 5 0 AMS MCV400 11.25 5.69 200 8 5 8 3 98 9 5 0 58 9 5 0 63 3 5 0 18 9 4 0 73 3 8 0 13 3 5 0 2 AMS MCV400 10 5.06 Total 196.33 100

120

100

80

60

40

20

0

M/c

B/D Hrs

STORM QCC

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2.0 OBSERVATION – COLLECT &ANALYSE DATA

PARETO ANALYSIS FOR FILTER MODULE BREAK DOWN DETAILS

Sno Machine 1 089407 2 033501 3 033502 4 033801 5 085839 6 089505 7 089506

Description B/D Freq. % % WINNER XL 2 6.25 40 36 100 100 9 3 .7 5 9 6 .8 7 ACE LT 20C 1 3.12 32 8 7 .5 8 1 .2 5 28 2 4 ACE LT 20C 0 0 24 75 20 LT-20CLASSIC 2 6.25 16 SPM 24 75 128 2 2 2 1 1 0 AMS MCV400 1 3.12 40 8 58 398 9 4 0733 80 18 9 50 63 3 50 18 95 053 35 0 2 AMS MCV400 2 6.25 Total 32 100

120

100

80

60

40

20

0

M/c

B/D Freq.

STORM QCC

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QC STORY

DRILLING SPM - 085839 Clutch unit Cylinder

Spindle unit

STORM QCC

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2.0 OBSERVATION – COLLECT &ANALYSE DATA

Breakdown Hours & Breakdown Frequency Of 085839 SPM For the month of Apr’ 05-Jun’05 BD HOURS

BD FREQUENCY

80

12

58

53

10

51

BD Freq.

BD hours

60 40 20 0

8

8

6 4

0 5 r'0 Ap

Ma

5 y'0

STORM QCC

Ju

5 n'0

5 r'0 Ap

5 y'0 a M

5 n'0 Ju

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PROCESS DETAILS

FLOW CHART FOR FILTER MODULE CELL CASTING FROM FOUNDRY

ACE LATHE LT 20C 033502

ACE LATHE LT 20C 033801

AMS MCV 400 089506

AMS WINNER 089407

FINAL INSPECTION& PACKING

STORM QCC

AMS MCV 400 089505

DEBURRING

ACE LATHE LT 20C 033501

DRILLINGSPM

WASHING

LEAK TESTING

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2.0 OBSERVATION-COLLECT ANALYSE DATA

PARETO ANALYSIS ON BREAKDOWN DETAILS OF DRILLING SPM (APR’05-JUN’05) SL.NO. 1 2 3 4 5

PROBLEMS Spindle unit not moving down Coolant not coming Component not clamped

B/D HRS 155 2.5 1.5

FREQ 17 2 1

2.5 0.5 162

3 1 24

Counter weight chain cut Air leak TOTAL

B/D HOURS100

99

98.6

98

240

97 96

95.6

20 15

91.66

83.33

17

95.67

100

100 80

70.83

60

10

40

95

STORM QCC

3

2

20 1

1 0

Air Leak

0

Component not clamped

Air Leak

93

5

Coolant not coming

0.5

Component not clamped

1.5

Counter weight chain cut

Spindle unit not moving down

0

2.5

Coolant not coming

2.5

94

Counter weight chain cut

80

Spindle unit not moving down

160

97.1

155

B/D FREQUENCY

100

99.6

320

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QC STORY

SPM - CLUTCH ENGAGING MECHANISM: Spindle Motor Worm wheel & Worm shaft Drive Driven Compressed Air

The Motor drive is transmitted to the worm wheel and to the worm Shaft. The drive from the worm shaft is Transmitted to the clutch plate drive shaft.

Pinion Lock Pin

Spindle unit

STORM QCC

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SPM - CLUTCH ENGAGING MECHANISM: Spindle Motor

The output from the valve actuates the cylinder And the driven shaft which is connected to the Piston got engaged to the clutch plate.

Worm wheel & Worm shaft Driver Driven

The pinion which is connected to the driven shaft Will rotates and the rack will starts to move down.

Compressed Air

Pinion

Lock Pin

Spindle unit

STORM QCC

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Spindle Motor

SPM - CLUTCH ENGAGING MECHANISM: After clutch plate gets engaged the air supply to the cylinder will cut off Worm wheel & Worm shaft

Then the single acting cylinder piston will retracts to its original position

Driver Driven

Mean while the spring loaded lock pin will move up and locks the clutch plate in engaging condition. Compressed Air

Pinion

Lock Pin

Spindle unit

STORM QCC

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WHY SPINDLE NOT MOVING UP/DOWN FREQUENTLY?

STORM QCC

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BRAIN STORMING

BRAIN STORMING WHY SPINDLE UNIT NOT MOVING UP/DOWN?

• • • • • • • • • • • • • • • • •

Pneumatic Valve struck up Cylinder struck up Counter weight chain cut Solenoid coil failure Wire cut Limit switch struck up Pressure switch failure Gear engagement failure Handle locking pin broken Clamp not working Motor not running Proper feed not coming Counter weight misaligned Pneumatic Push button failure Pneumatic hose cut Counter weight loaded Clutch pin got bend

STORM QCC

• • • • • • • • • • • • •

Component not clamped Cylinder seal failed Clutch pin broken Pin spring broken Spring weakened Spindle motor winding failure Loose connection Pinion gear broken Component wrong loading Low Voltage Clutch not engaging Air Pressure low FRL unit failure

0

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3.1 CAUSAL ANALYSIS

Man

Machine Gear not Lock pin Pneumatic pressure. engaging broken Hose cut Air Regulator failure Gear tooth pressure Clutch unit Worn out low Wrong Pr. Not engaging Valve failure setting Drive not Cylinder failure transmitting Push button failure Supply problem Spindle Component Motor not Shaft worn out Not clamped Loose connection running Wire cut WHY SPINDLE Supply problem Poor quality pin

Hose Weak

Lock pin broken

Frequent wear and tear

Method STORM QCC

UNIT NOT MOVING Due to Hose burst UP/DOWN? age

Seal damage

Hose stretched Cont. pressure in hose Air leakage Valve failure

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QC STORY

3.2 VALIDATION AND ROOT CAUSE IDENTIFICATION

LOOSE CONNECTION CHECK POINTS CONNECTION TIGHTNESS

SL.NO. LOCATION 1 IN ELECTRICAL PANEL 2 PLUG IN BOX 3 ACCESSORIES TIGHTING

OK

NOT OK

OK NOT OK

STORM QCC

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3.1 CAUSAL ANALYSIS

Low Pneumatic Machine Gear not Lock pin pressure. Hose cut engaging broken Regulator failure Gear teeth Clutch unit Worn out failure Valve failure Clutch not engaging Cylinder failure Voltage high Drive not Voltage variation transmitting Motor not Spindle running Shaft worn out Loose connection WHY SPINDLE voltage Voltage low

UNIT NOT MOVING UP/DOWN?

S l.nWo H A T W HERE W HY HOW 1 p n e u m a tic p re s sPureres s u re g a uRg e g u la to r fa ilu re C h e c k e d 2 vo lta g e C o n tro l P a n e Vl o lta g e va ria tio n C h e c k e d 3 L o c k p in b ro k e nC lu tc h u n it N o t w ith s ta n d in g loC ahde c k e d 4 C lu tc h n o t e n g a gC inlugtc h u n it N o fo rc e to c lu tc h Ce nh ge ac kg e d

STORM QCC

V A L ID A T IO N re g u la to r fu nInc tio s ign noific k a nt vo lta g e (4 2 0InVs)ig n ific a n t p in b ro k e n S ig n ific a n t c lu tc h n o t e nSg ig a gn eific d a nt

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QC STORY

3.1 CAUSAL ANALYSIS

Man Air pressure Component loaded Component not clamped low Wrong Pr. setting Wire cut Motor not Spindle struck running Loose connection

Supply problem

WHY SPINDLE UNIT NOT MOVING UP/DOWN?

W HA T W HE RE W HY HOW V A L ID A T IO N A ir p re s s ure lo w p re s s ure g a ug N oe c o rre c t s e tting (6 Cbhe a r)c k e d s e tting In o ks ig nific a nt L o o s e c o nne c tio n p a ne l b o a rd N o t tig hte ne d C he c k e d tig htne sInoskig nific a nt C o m p o ne nt no t c la mIn pfixture ed L a c k o f k no w le d g e C he c k e d no t c la m Sp eigdnific a nt

STORM QCC

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3.1 CAUSAL ANALYSIS

Poor quality pin

Due to Hose burst age Hose Weak

Lock pin broken

Frequent wear and tear

Seal damage

WHY SPINDLE UNIT NOT MOVING UP/DOWN?

Hose stretched Cont. pressure in hose

Air leakage Valve failure

Material

S l. N o . W hat W h e re W hy How V a lid a tio n 1 L o c k p in b r o k e nc lu tc h u nPito o r q u a lity mC ha etecria k e ld m a te ria l oInk s ig n ific a n t 2 H ose C ut S u p p ly lind eu e to a g in g C h e c k e d c o n d itio n In o k s ig n ific a n t

STORM QCC

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4.1 DEVELOPMENT OF SOLUTION

QC STORY

Validation of root cause 1:Lock Pin Broken

Driver Driven Compressed Air

WHY?

Not able to with stand load WHY?

Pinion

Uneven load acting on pin

Lock Pin

WHY?

No opposing force to clutch Spindle unit

WHY?

Design Constraint SOLUTION 1

Provide hydraulic cylinder for spindle up/down STORM QCC

SOLUTION 3

Provide pneumatic cylinder for spindle up/down SOLUTION 2

Modify pneumatic circuit DEPT CODE PRO. CODE PAGE NO

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4.1 DEVELOPMENT OF SOLUTION

QC STORY

Validation of root cause 2:Clutch not engaging WHY? Insufficient force to engage WHY? The contact surface between pin & clutch plate is less WHY? Design constraint SOLUTION 4

Provide additional pin to lock clutch STORM QCC

SOLUTION 6

Modify Pneumatic circuit SOLUTION 5

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4.1 DEVELOPMENT OF SOLUTION

QC STORY

Validation of root cause 3:Component not clamped in auto cycle WHY? Operator not clamped the component WHY? Lack of knowledge

Training to be given Clamping to be done in auto cycle to operator SOLUTION 7

STORM QCC

SOLUTION 8

Clamp condition to be interlocked in M/c SOLUTION 9

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4.1 DEVELOPMENT OF SOLUTION

QC STORY

Solution 1: Providing Hydraulic Cylinder For Spindle up/down S n o S o l u tio n P r o vid in g 1 h y d r a u lic c y lin d e r

A c t i o n A d v a n t a Dg iessa d v a n t a g e s 1 . P r o d u c t io n s t o p H y d r a u lic E lim in a t e d w h il e m o d ify in g . c y lin d e r t o b leo c k p in & 2 . D e s ig n c o s t fix e d in M / C C lu t c h u n it . h ig h . HYDRAULIC CYLINDER

Hence Solution Dropped STORM QCC

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4.1 DEVELOPMENT OF SOLUTION

QC STORY

Solution :2 Providing Pneumatic Cylinder For Spindle up/down S no

S o l u t io n

A c t io n

A d va n t a gDeiss a d va n t a g e s 1 . P r o d u c t io n s t o p P r o vid in g P n e u m a t ic E lim in a t e d w h il e m o d ify in g . 1 p n e u m a t ic c y lin d e r t o b Le o c k p in & 2 . D e s ig n c o s t c y lin d e r fix e d in M / C C lu t c h u n it . h ig h . PNEUMATIC CYLINDER

Hence Solution Dropped FEED CYLINDER

STORM QCC

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4.1 DEVELOPMENT OF SOLUTION

QC STORY

Solution 3: Modifying the Pneumatic circuit Sno

Solution

Action

Advantages

1.Lock pin will be eliminated. Clucth to be fully 2.Design cost Modify the 1 engaged by low. pneumatic circuit pneumatic 3.Clutch will be positively engaged.

Disadvantages

Nil

Hence Solution can be taken for implementation STORM QCC

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4.1 DEVELOPMENT OF SOLUTION

QC STORY

Solution 4: Sno

Provide additional pin to lock clutch

Solution

Additional lock 1 pin to be introduced

Action

Advantages Disadvantages

Additional lock 1.Uneven load 1.Difficult to fix pin to be fixed in can be additional lockpin the clutch unit in balanced. in the clutch unit M/C

Additional lock pin To be fixed

Hence Solution Dropped Existing Lock STORM Pin Location QCC

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4.1 DEVELOPMENT OF SOLUTION

QC STORY

Solution 5: Modifying the Pneumatic circuit Sno

Solution

Action

Advantages Disadvantages

1.Lock pin will be eliminated. Clucth to be fully 2.Design cost Modify the 1 engaged by low. pneumatic circuit pneumatic 3.Clutch will be positively engaged.

Nil

Hence Solution can be taken for implementation STORM QCC

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4.1 DEVELOPMENT OF SOLUTION

QC STORY

Solution 6: MODIFYING CLUTCH DESIGN Sno

Solution

1

M odifying the clutch design

Action

Adva nta ge sDisa dva nta ge s 1.Production stop Electro m agnetic Elim inated while m odifying. clutch to be lock pin & 2.Design cost introduced. Clutch unit. high.

Hence Solution Dropped STORM QCC

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4.1 DEVELOPMENT OF SOLUTION

QC STORY

Solution 7: Training to be given to operator Sno

Solution

Action

Adva nta ge sDisa dva nta ge s

Operator Training to be Training given to Possibilty of 1 m istake can given to operator.operator m aking m istake. be elim inated.

Hence Solution can be taken for implementation STORM QCC

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4.1 DEVELOPMENT OF SOLUTION

QC STORY

Solution 8: Clamping to be done in auto cycle Sno

Solution

Action

Clam ping to be Logic 1 done in auto m odification to cycle. be done.

Adva nta ge sDisa dva nta ge s 1.Design cost Com ponent high clam ped 2.Cycle m ay run autom atically with out clam p.

Hence Solution Dropped STORM QCC

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4.1 DEVELOPMENT OF SOLUTION

QC STORY

Solution 9: Clamping condition to be interlocked in machine Sno

Solution

Clam ping 1 contion to be interlocked

Action Clam ping interlock introduced in m achine.

Adva nta ge sDisa dva nta ge s Cycle will not run without Nil. com ponent clam ping.

Hence Solution can be taken for implementation STORM QCC

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QC STORY

4.2 Action plan

ACTION PLAN CHART FOR SOLUTION IMPLEMENTATION S l. N o . 1 2 3 4 5

A c tio n ( W h a t)

W he n W ho

A n a ly s e t h e P n e u m a t ic s e q u e n c e W M o d ify t h e p n e u m a t ic c irc u it W C o n n e c t io n w it h M a c h in e W C h e c k fo r p ro p e r o p e r a t io n W O b s e rva t io n W

STORM QCC

eek eek eek eek eek

1Q9 c 1Q9 c 2Q1 c 2Q2 c 2Q3 c

m m m m m

em em em em em

How bBe yr s o b s e r va t io n bMe ras in t e n a n c e d e p a rt m e n t bIne r st h e C lu c t h bMe ros n it o rin g t h e m a c h in e fu n c t io n bBe r es a k d o w n m o n it o r in g

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QC STORY

Before QCC

PNEUMATIC FEED CYLINDER

CIRCUIT DIAGRAM CLAMPING CYLINDER

P

P DECLAMP

CYCLE START

CYCLE START

P

STORM QCC

TIMER

DEPT CODE PRO. CODE PAGE NO

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QC STORY

Before QCC

5.2 BENEFITS

ELECTRICAL DIAGRAM

R Y B PE

STOP

MPCB

K1

START

CONTACTOR K1 (230vAC 50hz) Motor 3 phase

Spindle STORM QCC

motor

N DEPT CODE PRO. CODE PAGE NO

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45

4.2 Action plan

QC STORY

Before QCC:

SPM - CLUTCH ENGAGING MECHANISM: Driver Driven

Compressed Air

Pinion Lock Pin

Spindle unit STORM QCC

DEPT CODE PRO. CODE PAGE NO

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4.2 Action plan

QC STORY

Before QCC:

SPM - CLUTCH ENGAGING MECHANISM: Driver Driven

Compressed Air

Pinion Lock Pin

Spindle unit STORM QCC

DEPT CODE PRO. CODE PAGE NO

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02

47

4.2 Action plan

QC STORY

Before QCC:

SPM - CLUTCH ENGAGING MECHANISM: Driver Driven

Compressed Air

Pinion Lock Pin

Spindle unit STORM QCC

DEPT CODE PRO. CODE PAGE NO

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02

48

4.2 Action plan

QC STORY

Before QCC:

SPM - CLUTCH ENGAGING MECHANISM: Driver Driven

Compressed Air

Pinion Lock Pin

Spindle unit STORM QCC

DEPT CODE PRO. CODE PAGE NO

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49

QC STORY

After QCC: FEED CYLINDER

L2

CLAMPING CYLINDER Pressure Switch

Z14 3/2 WAY VALVE

Z12

5/2 WAY VALVE

P

P

CYCLE START

CYCLE START

DECLAMP

(L2) LIMIT SWITCH

P

STORM MODIFIED QCC

DEPT CODE PRO. CODE PAGE NO

CIRCUIT DIAGRAM

238

02

50

4.2 Action plan

QC STORY

After QCC:

SPM - CLUTCH ENGAGING MECHANISM: Driver Driven

Compressed Air

Pinion

Spindle unit STORM QCC

DEPT CODE PRO. CODE PAGE NO

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4.2 Action plan

QC STORY

After QCC:

SPM - CLUTCH ENGAGING MECHANISM: Driver Driven

Compressed Air

Pinion

Spindle unit STORM QCC

DEPT CODE PRO. CODE PAGE NO

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QC STORY

5.1 CHECK

OBSERVATION S.No 8.00am

10

11

12

13

14

15

16

17

18

19

20

21

22

23

23

24

25

26

27

28

29

4.00pm

WEEK 21

11.00pm S.No 8.00am

WEEK 22

4.00pm 11.00pm S.No 8.00am

WEEK 23

4.00pm 11.00pm

No Break down

STORM QCC

DEPT CODE PRO. CODE PAGE NO

Break down

238

02

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QC STORY

B/D HOURS OF SPM-085839 100

99.6

320

99

98.6

98

240 160

97.1

155

97 96

95.6

95

80

STORM QCC

94

0.5

93

Air Leak

Component not clamped

1.5

Counter weight chain cut

Spindle unit not moving down

2.5

Coolant not coming

2.5

0

THUS 95.6% OF THE PROBLEM SOLVED

100

DEPT CODE PRO. CODE PAGE NO

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QC STORY

We Decided to Kill the Other Phenomenon In SPM

Counter measure

STORM QCC

DEPT CODE PRO. CODE PAGE NO

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02

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QC STORY

WE DECIDED TO SOLVE THE REMAINING

4.4%

99.6

320

OF THE PROBLEM.

100

98.6 97.1

155

97 96

95.6

95

80 1.5

0.5

94 93

Counter weight chain cut Air Leak

Spindle unit not getting up/down

0

2.5

Coolant not coming Spindle motor not rotating

2.5

99 98

240 160

100

Remaining Problems : 1. Spindle coolant not coming. 2. Component not clamping. 3. Counter weight chain cut. 4. Air leak from the hose. STORM QCC

DEPT CODE PRO. CODE PAGE NO

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4.1 DEVELOPMENT OF SOLUTION

QC STORY

Phenomenon1:Coolant not coming Coolant not coming WHY?

Burr blocked in the pipe line WHY?

Coolant coming along with burr WHY?

Filter not provided CM STORM QCC

‘Y’ Strainer provided in the Line DEPT CODE PRO. CODE PAGE NO

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02

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QC STORY

COUNTER MEASURE TAKEN FOR PHENOMENON: 1 AFTER

BEFORE

“Y” STRAINER

STORM QCC

DEPT CODE PRO. CODE PAGE NO

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4.1 DEVELOPMENT OF SOLUTION

QC STORY

Phenomenon2:Component not clamping Component not clamped WHY?

Air Leak from the cylinder WHY?

Cylinder seal worn out WHY?

Due to aging CM STORM QCC

Replaced the seals DEPT CODE PRO. CODE PAGE NO

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59

4.1 DEVELOPMENT OF SOLUTION

QC STORY

Phenomenon3 : Counterweight chain cut Chain cut WHY?

Chain not able to withstand load WHY?

WHY? WHY?

Ineffectiveness in weight resting Low tension spring design constraint

CM STORM QCC

Spring tension to be increased

DEPT CODE PRO. CODE PAGE NO

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QC STORY

COUNTER MEASURE TAKEN FOR PHENOMENON: 3 BEFORE

Counter weight

AFTER

High tension Low tension

spring

spring

STORM QCC

DEPT CODE PRO. CODE PAGE NO

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61

4.1 DEVELOPMENT OF SOLUTION

QC STORY

Phenomenon 4:Air leak from hose Air leak from hose WHY?

Air hose burst WHY?

Not able to withstand pressure WHY?

Due to aging CM STORM QCC

Replaced the Hose DEPT CODE PRO. CODE PAGE NO

238

02

62

QC STORY

5.1 CHECK

ELIMINATED BREAKDOWN FROM 162 Hrs TO ZERO TILL NOW 80 AFTER QCC

BEFORE QCC

58

53

51

BD HRS

60 40 20

STORM QCC

0

0

0 0

6 M ar '0 6 A pr '0 6 M ay '0 6 Ju n' 06

0

b' 0

Fe

Ja

ec '

0

n' 06

0

05

05

0

D

ov '

'0 5

0

N

5

0 O ct

ep '0

05

0

S

5

ug ' A

l'0

5

Ju

'0

n' 0 Ju

M ay

pr '0 A

5

0 5

0

BREAK DOWN HRS

DEPT CODE PRO. CODE PAGE NO

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QC STORY

5.1 CHECK

REVISED GANTT CHART W EEK NO ACTIVITIES

RESP

DATA COLLECTION

TEAM

14

15

16

17

18

19

20

21

22

23

24

25

PROBLEM SELECTION TEAM ANALYSIS

TEAM

SOLUTION SELECTION TEAM IMPLEMENTATION

TEAM

OBSERVATION

TEAM

STANDARDISATION

TEAM

STORM QCC

PLAN ACTUAL

DEPT CODE PRO. CODE PAGE NO

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QC STORY

5.1 CHECK

Comparison S.No Before QCC 1 Clutch Not user friendly 2 Lock pin used to engage clutch 3 Pneumatic Timer used 4 Spares not available in market 5 Complication of electrical & pneumatic circuit No interlock for component 6 clamp Difficult to set the drill 7 depth

STORM QCC

After QCC Clutch User friendly Pneumatic pressure used to engage clutch Timer eliminated Availibility of spares are easy Simple electrical & pneumatic circuit Interlock provided for component clamp Drill depth can be adjusted easily.

DEPT CODE PRO. CODE PAGE NO

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QC STORY

5.2 BENEFITS

TANGIBLE BENEFITS SPM Spindle unit Up/Down breakdown frequency reduced



from 24 to 0.

Cost of drill bit:Rs.1400/Cost of three Broken drill bits:3*1400=Rs.4200 Cost of clutch lock pin:Rs.400/Total no. of times Lock pin broken:3 times Total cost of pin:3*400=Rs.1200/Cost of Pneumatic timer is:Rs.4822/Total cost saving of this project:4200+1200+4822=Rs.10622/Cost of Pressure switch used in this project:Rs.600/Net saving:Rs.10622-600=Rs.10022/STORM QCC

DEPT CODE PRO. CODE PAGE NO

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QC STORY

5.2 BENEFITS

INTANGIBLE BENEFITS •

Machine Safety Improved.

•

Customer Satisfaction Achieved.

•

Machine availability Increased.

•

Machine Malfunction (Due To up/down) Eliminated.

•

Machine accident eliminated.

•

Lock pin eliminated.

•

Pneumatic timer eliminated.

•

Component clamp interlock introduced.

STORM QCC

DEPT CODE PRO. CODE PAGE NO

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QC STORY

6.0 Standardization

Standardization : Sl no

Activity

Necessity Where Resp TS 16949

PMD

PN

requirements 1

DOCUMENTATION

2

MODIFICATION

3

Entered the modification details in history cards & also a copy in the Machine code folder

For Reducing PMD Break down

UPDATION IN PM For Reducing PMD CHECKLIST Break down

STORM QCC

Method

Team Modified the pneumatic circuit

PN

Entered the Check points in PM check list.

DEPT CODE PRO. CODE PAGE NO

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QC STORY

5.1 CHECK 6.0 Standardization

PM Master Check List 2

Check theconditionof MPCB

Half yearly

3

check tightness for all proximity&sensor locknut

Half yearly

4

Check pilot operatedcoolant switchingonvalvefor its normal workingcondition.

Half yearly

5

Fill GreaseinSpindle& Multi gear box

Half yearly

6

Cleanburr incoolant line, filter &coolant tank

Monthly

7

DrainmoistureinFilter bowel &clean

Monthly

8

Tightenall Coolant pipefittings

Monthly

9

Tightenall hydraulic linefittings

Monthly

10

Removethedrainedoil fromtheSlide

Monthly

11

Check theauto/manual switch condition

Quarterly

12

Check conditionof terminal connector for hyd.&coolant

Quarterly

13

Tight all thesolenoidcoil connections

Quarterly

14

Tight the wireconnections intheP.B

Quarterly

15

Tight thePLCunit cableconnection

Quarterly

16

Check thelever typelimitswitchfor cyclestart for its normal workingcondition.

Quarterly

17

Check mainHydraulic pressurefor 4-5kgf/cm2

Quarterly

18

Routeall hoses clearly

Quarterly

19

Check theconditionof thepneumatic hoses

Quarterly

20

Check theconditionof thepneumatic cylinder seal condition

Quarterly

21

Check theconditionof thecounetr weight chain

Quarterly

22

Cleanthelubricationunit filter

Quarterly

23

Replacethedamagedluboil hoses

Quarterly

Sl.No

CheckPoints

STORM QCC

Frequency

DEPT CODE PRO. CODE PAGE NO

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02

69

QC STORY

6.1 POKA YOKE

Prevent error Detect error

Shut down Control Alarm

DESCRIPTION OF THE PROCESS : Ensure component clamping in Filter module SPM Before improvement Contactor STOP

L1 L2 L3

After improvement

L1 L2 L3

Contactor

START

Pressure Switch

OLR

OLR

M

M N

Without clamping cycle will run

STORM QCC

Clamp Signal

N

Without clamping cycle will not run

DEPT CODE PRO. CODE PAGE NO

238

02

70

QC Tools

QC STORY

TOOLS

USED

Check sheet

J a n ' 9 F8 e b T e s te d 8 2 6 2 7 8 R e j e c t i o n8 0 24 % R e j e c t 9i o. 7 n 8 . 6

Pareto Diagram

' M9 8 a r ' 9T 8o t a l 2 16 49 4 24 48 11 .1

10 0

1 00

1 00

96

80

80

60

60

60 30

40

40 10

20

20

0

Cause & Effect Diagram

4

0 Ex c e s s S ta n d o u t

O f f L e ak

L e s s Ou tp ut

Graph & Control Chart 800 600

Histogram

400 200 0

QC tools

92-93 93-94 94-95 95-96 96-97 97-98 98-99

Scatter Diagram Stratification

OTHER TECHNICS USED:

1.7 1.5 1.3 1.1 0.9 0.7 36 .1 36 .2 3 6.3 3 6.4 3 6.5 36.6 36.7 36.8 36.9

37

37.1 37.2 37.3

12 11.1 10 8

8.6

6

6.8

4 2

ShiftA

0 Feb'98

STORM QCC

Shift A

M ar'98

1. 2. 3. 4.

FLOW CHART KAIZEN SHEET PHENOMENA MATRIX POKA YOKE DEPT CODE PRO. CODE PAGE NO

238

02

71

QC STORY Sundaram clayton limited DCD PMD Machining Jipm- TPM

Machine : 085839 Unit : DCD-Machining Month : May ‘05 Ref : PMD/M/038 Provide a Y strainer in the To eliminate breakdown due to burr Kaizen Theme : Target & Target Date: Delivery Line. Blockage. Provide a Y strainer in the Counter measure : Problem : Delivery Line. Benefits / Results after Before Counter Burr blocked in the coolant line Implementation : Measure : Analysis :

KAIZEN SHEET

Why? Burr blocked in the coolant line Why? Burr entered in the coolant line Why? Burr carryover along with coolant After Counter Measure : Why? No filter provided

Improvement: Provide a filter in the Delivery line. Root Cause : Weak design

No burr blockage in the Coolant line.

Scope & Plan for horizontal deployment :

For all spm machines

Idea : Provide

a filter in the delivery line STORM QCC

DEPT CODE PRO. CODE PAGE NO

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02

72

QC STORY Sundaram clayton limited DCD PMD Machining Jipm- TPM

Machine : 085839 Unit : DCD-Machining Month : May ‘05 Ref : PMD/M/038 Provide a Y strainer in the Target & Target Date: Delivery Line.

KAIZEN SHEET

Kaizen Theme : To eliminate Counter weight chain cut.

Counter measure : Changed low to high tension spring

Problem :

Counter weight chain cut

Before Counter Measure :

Benefits / Results after Implementation :

Counter weight chain cut eliminated Spring breakage avoided.

Analysis :

Why?

Chain cut

Why? Chain not able to withstand load Why? Ineffectiveness in weight resting After Counter Measure : Why? Low tension spring Why? design constraint

Scope & Plan for horizontal deployment :

Improvement: Introduced high tension spring Root Cause : Design constraint Idea : Introducing

spring STORM QCC

a high tension DEPT CODE PRO. CODE PAGE NO

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02

73

QC STORY

5.1 CHECK

Phenomenon Matrix BREAKDOW NPHENOMENONMATRIX M achine:085839

Root Cause

Jun'05

KaizenIdea/ Counter measure ActionCat. W K6

Pneum atic engagetim eless

P neum atic circuit m odified

Burr entry

Y-strainer provided

CM

W K7

July'05

W K8

W K9

W K1 0

W K1 1

Aug'05

W K1 2

W K1 3

W K1 4

W K1 5

W K1 6

Sep'05 W K1 7

W K1 8

W K1 9

W K20

W K21 W K22

1

3

3

5

0

0

0

0

0

0

0

0

0

0

0

0

0

KAIZEN

-

-

-

-

-

-

-

C

1

0

0

0

0

0

0

0

0

wornout

Seal conditiontobecheckedinC P M M

-

-

-

-

-

-

-

-

C

0

0

0

0

0

0

0

0

Counter weight chaincut

Restingspringchanged

-

-

-

-

-

-

-

-

3

0

0

0

0

0

0

0

0

Hosehardened

Hoseconditiontobecheckedin CM P m

-

-

-

-

-

-

-

-

C

0

0

0

C

C

0

C

STORM QCC

KAIZEN

Break Down

NO 0

1

Break Down

KAIZEN

DEPT CODE PRO. CODE PAGE NO

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02

74

QC STORY

7.0 CONCLUSION

Conclusion : Small change in design will leads to Big change in machine availability.

STORM QCC

DEPT CODE PRO. CODE PAGE NO

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02

75

QC STORY

Next Project

OUR FUTURE PLAN

*REDUCE BREAKDOWN HARDINGE GROUP MACHINES.

STORM QCC

DEPT CODE PRO. CODE PAGE NO

238

02

76

QC STORY

THANKS

THANK YOU

STORM QCC

DEPT CODE PRO. CODE PAGE NO

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02

77

QC STORY

INFO ABOUT CLUTCH: TO TRANSMIT MOTION WHEN NEEDED DEPENDS ON LAW OF FRICTION FRICTION HELPS TO TRANSMIT MOTION

STORM QCC

DEPT CODE PRO. CODE PAGE NO

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02

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QC STORY

STORM QCC

DEPT CODE PRO. CODE PAGE NO

238

02

79

QC STORY

WELCOME

Sundaram Clayton Ltd Die casting Division STORM QCC WELCOMES YOU ALL FOR OUR SECOND PROJECT PRESENTATION STORM QCC

DEPT CODE PRO. CODE PAGE NO

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02

80

QC STORY

2.0 OBSERVATION – COLLECT &ANALYSE DATA

DATA COLLECTION FOR CELL WISE B/D FREQ. & HOURS (FROM APR‘05 - JUN‘05) 196.33

200 150 100 50

Lub Module

Head FF

Honda Oil pan

Ford Oil pan

Honda Case chain

MY 4.5

ISX Fwh

Lub Module

Head FF

Honda Oil pan

Ford Oil pan

Honda Case chain

MY 4.5

ISX Fwh

Cloc

Honda Case Chain

Filter Module

Gear Housing

0

Visteon

Visteon Gear Housing Filter Module Honda Case Chain cloc Lube Module Head FF Honda Oilpan Ford Oilpan Honda Casechain MY 4.5-Holset ISX-Flywheel Hsg

Hours Frequency 7.24 3 17.76 6 196.33 32 25.47 6 35.57 8 50.79 14 61.89 5 31 4 4.17 1 23 6 12 5 82 17

BD Hours

Hours

Cell

Frequency

Frequency

40

32

30 20 10

STORM QCC

Cloc

Honda Case Chain

Filter Module

Gear Housing

Visteon

0

DEPT CODE PRO. CODE PAGE NO

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02

81

QC STORY

Before QCC

OLD CIRCUIT DIAGRAM

FEED CYLINDER

L1 CLAMPING CYLINDER

Pressure Switch

P

DECLAMP CYCLE START

CYCLE START

P

STORM QCC

TIMER

(L1) LIMIT SWITCH

DEPT CODE PRO. CODE PAGE NO

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02

82

QC STORY FEED CYLINDER

After QCC:

L1

L2

CLAMPING CYLINDER

Z12

Z14

Z14

5/2 WAY VALVE

Z12

5/2 WAY VALVE

P

P

CYCLE START

CYCLE START

(L1) LIMIT SWITCH

P

STORM QCC

(L2) LIMIT SWITCH

DECLAMP

DEPT CODE PRO. CODE PAGE NO

MODIFIED CIRCUIT DIAGRAM

238

02

83

4.2 Action plan

QC STORY

Solution 4: Modifying the Pneumatic circuit FEED CYLINDER

Z14

L1

L2

CLAMPING CYLINDER

Driver Driven Compressed Air

Pressure Switch

Z12

Z14

P

5/2 WAY VALVE

Z12

5/2 WAY VALVE P

Pinion

CYCLE START CYCLE START

P

DECLAMP

(L2) LIMIT SWITCH

(L1) LIMIT SWITCH

Spindle unit

MODIFIED CIRCUIT DIAGRAM STORM QCC

DEPT CODE PRO. CODE PAGE NO

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02

84

QC STORY

M

A

O

F

I

T

D CAM

F

PLATE

I C

E

A T

R

I O

LIMIT SWITCH STORM QCC

N DEPT CODE PRO. CODE PAGE NO

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02

85

QC STORY

RANK ‘A’ –PM SCHEDULE Sl.no

M achineno

Machine Description

Cell Description

Unit

W14 1

2

3

4

W15 5 6

7

8

9

10

11

12

W16 13

14

15

16

Cumm ins 1

360102

2

089402

3

089501

4

LEAKTEST

CLOC

Cummins

AMSW INNERX L

CLOC

Cummins

AMSMCV400

CLOC

Cummins

089502

AMSMCV400

CLOC

Cummins

5

360137

LEAKTEST

CLOC

Cummins

6

081502

AMSMCV300

DCX

Cummins

7

081503

AMSMCV300

DCX

Cummins

8

089304

DAHLIH1020

Gear housing

Cummins

9

089301

DAHLIH1020

Gear housing

Cummins

10

089401

AM SW INNER

Gear housing

Cummins

11

089603

12

089102

13

085831

15

081402

16

HARDINGE

ISX

Cummins

ISX

Cummins

ISX

Cummins

AMSMCV600

ISX

Cummins

089202

DAHLIH720

ISX

Cummins

17

089605

HARDINGE

ISX

Cummins

18

089604

HARDINGE

ISX

Cummins

19

089204

DAHLIH720

ISX

Cummins

20

310101

VT80I

ISX

Cummins

21

310102

VT80II

ISX

Cummins

22

089302

DAHLIH1020

M11

Cummins

23

089203

DAHLIH720

SOVB

Cummins

24

081401

AMSMCV600

M idrange

25

89701

26 27

AMSMCV500 SPM

Cummins

CHIRON

LUBEMODULE

Fleetguard

089507

AMS400

PRIMERPUMP

Fleetguard

89601

HARDINGE

LUBEMODULE

Fleetguard

28

89506

AMS400

FILTERMODULE

Fleetguard

29

33502

ACELT20C

FILTERMODULE

Fleetguard

30

033108

GEDEEW EILER

HeadFF Fleetguard

STORM QCC

DEPT CODE PRO. CODE PAGE NO

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QC STORY

E Q U IP M E N T R A N K IN G C R IT E R IA EQUIPMEN T R AN KIN G C R ITER IA C E LL: C LOC Crite ria

A

B

C

ca te gory 033007

033201

089402

LA THE -I LA THE -II V M C-I Hygie ne & S a fe ty

Failure w ould cause Failure w ould c aus e f ire/explosion ris k or saf ety/hygiene risk or serious environmental environmental problem problem

089501

089502

V M C-II

V M C-III

086309

280412

360102

DIA 5 S P M DIA 16 S PWMA S HINGL/TE S T-I

C

C

C

C

C

C

C

C

C

Mac hine quality def ects Mac hine quality def ec tsMachine quality def ects w ith > 1% rejection w ith 0.3 - 1% rejection w ith < 0.3% rejec tion

C

B

C

C

C

C

C

C

C

Takt time is 75% to 100%

Takt time is < 75%

C

A

C

C

A

C

C

C

B

Operation can be carried out in other mac hines

Other Equipment

B

A

A

A

A

A

B

C

B

Fre q ue ncy o f Number of equipment Number of equipment Number of equipment failure s & f ailures is >10 / month f ailures is 5 - 10 / month f ailures is < 5 / month M ain tainab ility

C

B

A

A

A

B

C

C

C

M inor Number of minor stops isNumber of minor stops Number of minor stops > 3 per 8 hours is 1 - 3 per 8 hour is <1 per 8 hour S toppa ge s

C

B

B

B

B

C

C

C

C

Qua lity

Ope ra ting S ta tus

Takt time is 100%

Im pa ct on No c ontigency f or the P roduction equipment (Contige ncy

STORM QCC

Other Equipment

DEPT CODE PRO. CODE PAGE NO

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02

87

QC STORY

2.0 OBSERVATION-COLLECT ANALYSE DATA

SPM SPINDLE UNIT WORKING MECHANISM OF SPINDLE UNIT: Pinion WHEN THE SPINDLE MOTOR ROTATES IT TRANSMITS THE DRIVE TO THE WORM WHEEL AND WORM SHAFT.THE DRIVE FROM THE WORM SHAFT IS TRANSMITTED TO THE CLUTCH DRIVER PLATE.

THE OUTPUT FROM THE VALVE ACTUATES THE CYLINDER AND THE DRIVEN PLATE WHICH IS CONNECTED TO THE PISTON GOT ENGAGED TO THE CLUTCH PLATE.THE PINION WHICH IS Pinion CONNECTED TO THE DRIVEN SHAFT WILL ROTATES AND THE RACK (SPINDLE UNIT) WILL STARTS TO MOVE DOWN. STORM QCC

Driver Driven Compressed Air

Lock Pin Spindle unit

Driver Driven Compressed Air Lock Pin Spindle unit DEPT CODE PRO. CODE PAGE NO

238

02

88

QC STORY

TANGIBLE BENEFITS: Cost of drill bit:Rs.1400/Cost of three Broken drill bits:3*1400=Rs.4200 Cost of clutch lock pin:Rs.400/Total no. of times Lock pin broken:3 times Total cost of pin:3*400=Rs.1200 Cost of Pneumatic timer is:Rs.4822/Total cost saving of this project:4200+1200+4822=10622 Cost of Pressure switch used in this project:Rs.600/Net saving:10622-600=Rs.10022 STORM QCC

DEPT CODE PRO. CODE PAGE NO

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89