Mt Qm Pillar d5953

QM

Micro Turners Pantnagar QM Pillar Activity Presentation By S K Verma Date : 19th March-2011 MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

1

CONTENTS TOPICS

S. NO.

QM SLIDE NO.

1

Background

3

2

Aim

4

3

Structure- QM Pillar

5

4

Targets

6

5

Scope

7

6

Activities on Customer Complaints - Warranty

08-19

7

Activities on Customer Complaints - EFR

20-28

8

Activities on Customer Complaints

29-50

9

Activities on In-process Rejection

51-69

10

Future Plan

MICRO TURNERS PANTNAGAR

70 TPM - The Prime Mover Towards Excellence

2

BACKGROUND

QM

In-house Rejection

Warranty Rejection WHY QM ?

Inspection standard not adequate


Customer Complaint

Reactive Approach


3

Aim- QM Pillar

QM

To establish defect free manufacturing process, where quality is built into process, leading to consistent product performance and quality into the hands of customer.



4

QM Pillar - STRUCTURE

QM

SK Verma (PILLAR CHAIRMAN)

Mr. Praveen Kumar ( Machine Shop )

Mr. Sanjay Verma

Mr. Surender Kumar


Mr. RN Singh ( Machine Shop )

Mr. VK Singh

Mr. Gaurav Tyagi

Mr. DD Giri ( HT & Plating )

Mr. Ajoy Mukharji


Mr. Manoj Bangali

5

QM-Targets



QM

6

QM SCOPE

QM

QM ACTIVITY

Customer complaint prevention activities

In process defect prevention activities

Vendor component defect prevention activities

Warranty

M/c Shop

Bought out Components

EFR

Heat treatment

Job Work

Customer Complaint s

plating

In house



7

QM

Total warranty claims received till date from 6 to 24 months of Vehicles sold month or 30,000 kms, whichever is earlier.



8

WARRANTY Warranty Claims Analysis Flow

QM

Receipt of field parts / Report from field

Analysis by CFT of all interfacing function Action identification

Manufacturing related

Non conformance (NC to drawing specification)


Design related

Basic Design Error

Robustness to Mfg. & Service

Field related

Periodic maintenanc e issues


Usage issues

9

WARRANTY Non Conformance (NC to drawing specification) Analysis

Manufacturing related

Can detect

Make it detectable

Inspection Side Inspectio n Poka

Inspection Plan inadequate

Cause Side

Difference in standards

Inspection Method wrong

Daily Check List

MICRO

Update PQ Update PRBFM Update Check sheets TPM Update Inspection agreement TURNERS PANTNAGAR

Material nonconformanc e

Establish cause source through QA matrix Identify 4M & T conditions Kaizen for maintaining 4M & T conditions Sustenanc

Identify further possibilities & countermeasure

Surface coating nonconformanc e

Dimensional nonconformance

Update Change/ Communize with reference Inspection to respective Plan

Cannot detect

Cause Side

Inspection Plan

Poka Yoke

QM

e Machine PM & JH

Material PPC & QM

Method KK, JH & PM

- The Prime Mover Towards Excellence

Men

Tool

E&T & QM

KK & PM

10

WARRANTY



QM

11

WARRANTY

QM

DEFECT PHENOMENA MATRIX



12

WARRANTY



QM

13

WARRANTY

QM

DEFECT PHENOMENA MATRIX



14

WARRANTY ANALYSIS &ACTION

Part name Model: Phenomena

QM

: Shaft Kick : All Model : Crack / Broken

Probable Causes

Actions

1

Material Property – 16MnCr5

Checked & found - OK

2

Surface Hardness – 77/81 HRA

Checked & found – OK ( 79/80 HRA )

3

Core Hardness – 25/45 HRC

Checked & found – OK ( 38 HRC )

4

Case depth – 0.10/0.30 mm

Checked & found – OK ( 0.30 mm )

5.

Plating Process – Hydrogen de-embrittle ment treatment – not done / not done properly .

Ensure 100% Hydrogen deembrittle ment treatment in Plating.

6.

Weak Design

Design has Changed by BAL (Radius 3.5 to 4.2 mm & Dia 10 mm to 11.5 mm )

Sr. no.



15

WARRANTY

QM

Action Action: :Ensure Ensure100 100%%Hydrogen Hydrogende-embrittlement de-embrittlementTreatment Treatmentduring duringPlating Plating MICRO TURNERS PANTNAGAR


16

WARRANTY

QM

IMPROVEMENT SHEET Problem/Status:- Crack / Broken

Date of Implementation :- July- 2010

BEFORE

AFTER

Probable Cause:-

Counter Measure:-

-Weak Design.

1.

Radius 3.5 mm change to 4.2 mm

2.

Diameter 10 mm change to 11.5 mm

Idea:-

Change Design



17

WARRANTY RESULTS

Action ActionTaken Taken July,10 July,10

QM

G O O D

Old OldPart Part–– Manufactured Manufactured ininmarch,10 march,10



18

WARRANTY

QM

Interaction with CQA BAL Akurdi for Interaction with CQA BAL Akurdi for understanding & corrective actions understanding & corrective actions



19

QM

Warranty claims received in less then 6 months of Vehicles sold or less then 3000kms, whichever is earlier.



20

EARLY FAILURE

AS per SAP data AS per SAP data


As per Mfg. NC As per Mfg. NC


QM

G G O O O O D D

21

EARLY FAILURE – DEFECT PHENOMENA MATRIX



QM

22

EARLY FAILURE



QM

23

EFR (DEFECT PHENOMENA MATRIX)



QM

24

ANALYSIS & ACTION - NOISY

QM

Noisy

Drive Assembly

Total Composite Tooth to Tooth Error 0.10 Error 0.03

OK OK 1. 2. 3.

Gear Starter Clutch

Tooth Profile Error More

OK OK

OK OK

First Pc Inspection & Confirmed In- Process – 2/250 pcs Inspection. Final Stage – 100 % Inspection 1. 2.


Total Composite Tooth to Tooth Error 0.10 Error 0.03

OK OK 1. 2. 3.

Tooth Profile Error More

OK OK

First Pc Inspection & Confirmed In- Process – 2/250 pcs Inspection. Final Stage – 100 % Inspection

KAIZEN

First Pc Inspection & Confirmed In- Process – 1/1000 pcs Inspection.


25

ACTIONS ON NOISY – Gear Starter clutch



QM

26

EFR RESULTS

New NewParts Parts Supply Started Supply Started

QM

GG OO OO DD Action Action Taken Taken



27

WARRANTY

QM

Interaction with CQA BAL Akurdi for Interaction with CQA BAL Akurdi for understanding & corrective actions understanding & corrective actions



28

QM



29

CUSTOMER COMPLAINT APPROACH



QM

30

CUSTOMER COMPLAINT

QM

1.1. BAL BAL“Q” “Q”Bronze BronzeAwardAward-Oct, Oct,2008 2008 2.2. BAL “Q” Silver AwardApr,2009 BAL “Q” Silver Award- Apr,2009 3.3. BAL BAL“Q” “Q”Gold GoldAwardAward-QualifiedQualified-Apr,2010 Apr,2010 New NewParts PartsSupply Supplystarted started



31

CUSTOMER COMPLAINT

QM

DEFECT PHENOMENA MONITORING



32

CUSTOMER COMPLAINT

QM

ANALYSIS & ACTIONS



33

CUSTOMER COMPLAINT

QM

ANALYSIS & ACTIONS



34

ACTION ON STEP AT DIA. IN DRIVE ASSLY.



QM

35

CUSTOMER COMPLAINT

QM

IMPROVEMENT SHEET Problem/Status:- Step on Dia. In Drive Assly

Date of Implementation :- 10.10.10

BEFORE

AFTER

Root Cause:-No mechanism for locking the Horizontal slide.

Counter Measure:- Plate & Bolt is attached with Machine to lock the Horizontal Slide

Idea:- TO Make a provision to lock the Horizontal Slide



36

CUSTOMER COMPLAINT



QM

37

CUSTOMER COMPLAINT

QM

IMPROVEMENT SHEET Problem/Status:- Total length Over size – Bearing

Date of Implementation :- 18.11.2010

Race BEFORE

AFTER

INSPECTION BY MICROMETER DURING SETTING

INSPECTION BY SNAP GAUGE DURING SETTING

Root Cause:-

Counter Measure:- Snap Gauge is provided on machine to avoid checking

- During setting – Error in reading of Micrometer.

error.

Idea:- TO eliminate Inspection checking Error.



38

Zero Customer Complaint Sustenance

QM

Zero Customer Complaint Sustained By:1. Counter-measures on components arrested at Final inspection stage. 2. PDI operator recognition 3. “ Q “ Methodology Implementation.



39


QM

1. Counter-measures on components arrested at PDI. Daily defect monitoring sheet



40


QM

3. PDI operator recognition



41

Sustenance for Zero In-Process Defect



QM

42


QM

Component Study



43


QM

Critical dimension identification



44




QM

45




QM

46




QM

47




QM

48




QM

49




QM

50

QM



51

IN-HOUSE REJECTION



QM

52

IN-HOUSE REJECTION

QM

GOOD



53

IN-HOUSE REJECTION

QM

PROCESS WISE PPM & DEFECT PHENOMENA 2010-11



54

IN-HOUSE REJECTION

QM

DEFECT PHENOMENA MATRIX – FOR FIRST TWO HIGH VALUE REJECTION COST



55

IN-HOUSE REJECTION

QM

ANALYSIS & ACTIONS



56

IN-HOUSE REJECTION



QM

57

IN-HOUSE REJECTION


-

Kaizen


QM

58

IN-HOUSE REJECTION


-Kaizen (Plating)


QM

59

IN-HOUSE REJECTION



QM

60

IN-HOUSE REJECTION



QM

61

IN-HOUSE REJECTION

QM

ANALYSIS & ACTIONS - Sprocket



62

IN-HOUSE REJECTION



QM

63

IN-HOUSE REJECTION

QM

Defect DefectPhenomena Phenomena- -88nos. nos.

HappenedHappened-22 Kaizen Kaizen - -22

PokaPoka- In-process In-process Yoke Inspection Yoke Inspection


May MayHappen Happen- -66

Kaizen Kaizen

PokaPokaYoke Yoke


In-process In-process Inspection Inspection- -66

64

IN-HOUSE REJECTION



QM

65

IN-HOUSE REJECTION



QM

66

IN-HOUSE REJECTION

QM

RESULTS – SPROCKET CELL

All AllActions ActionsCompleted Completed

Results Results GG OO OO DD



67

IN-HOUSE REJECTION



QM

68

IN-HOUSE REJECTION



QM

69

FUTURE PLAN



QM

70

QM

THANK YOU MICRO TURNERS PANTNAGAR


71

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