8 d lift onload ft
TRANSCRIPT
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Objective of 8 D Review
Progress review of all the 10 8D Teams
Out come of the 8 D steps
Support required by teams from
PU HeadsMr. Anil Menon
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8 D Problem Solving on
FT - Hydraulic Lift On Load
Project start Date - 14 Sept12
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Progress Summary :
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D2 : Problem Definition
S.No Factors Problem Details Comparative Study Inference (which should
be analysed further )Is Is not
Differences / Changes
1WHO reported the problem? 1. Test Rig 1.FTA Tet Rig is equipped with Pressure Gauge
which is showing the pressure value/directly
indication of the problem. Whereas in FTA
there is no pressure gauge, Engine noise level
is the criteria to identify the problem which
depends on skill set of Operator.
1. Variable inspection
facility is not available at
FTA level.
2. Operator dependent
inspection at FTA.
2WHAT is part
number/description?
FT 30, 45, VMX, AMX, FT 60,
FT 60 SMX, FT 60/65 EPI.
Nil Problem persists in all FT models.
Concentration is more in Heavy Liftcompared to Normal Lift.
Capacity of normal lift is
1050 kg, & heavy lift
1500 kg load variation
3WHAT is problem ? After Lifting, Lift not
achieving neutral circuit.
Pump is taking load.
Nil
4WHAT is measurement
method ?
Hyd. Test Rig using Pr. Gauge with 'OK' /
'NOT OK' decisions (Attribute).5What is potential/actual
effect to the customer / in
the field (As stated by
Customer).
Engine taking load by noise difference,
Pump failure.
6What could be commercial
impact over this problem.
Increase in Cost of Poor
Quality.
7If the product is being
assembled in using multiplelines, which lines is causing
problem ?
N/A since being assembled in
single line.
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D2 : Problem Definition
S.No Factors Problem Details Comparative Study Inference (which
should be analysed
further )Is Is notDifferences / Changes
8 If the product is being tested in usingdifferent Test Rigs, which Test Rig
problems are reported ?
On all 3 test rigs
9 What item has got the problem. Cylinders sub assly. (
in most of the
cases).
It is not in all the cases. Data not available To conduct further
study on OK assy and
Not OK assy.
linkages of hydrualic
assly. (in few cases).
Its not in all the cases. To conduct further
study on OK assy and
Not OK assy.
10 What all are the items which can lead
the problem (Boundary Diagram).
Attached
11 What similar product could has the
problem but doesnot seen/reported.
N/A.
12 When the problem was first
noticed/found ?
Since beginning.
13 When it is noticed after 1st time? Continuous
14 Where on the components the problemnoticed ?
N/A.
15 Where is the process flow/ sequence
the problem is noticed?
Test Rig Operation
no. 110
16 Where on the product, geographically
the problem was seen?
N/A.
17 When in the product life cycle, this
problem is noticed,
1. Infant mortality
2.Warranty Failures3.Due to wear and tear ?
Infant Mortality
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11.8
15.9
22.8
19.2 19.2
40.2
26.5
9.4
18.721.3
25.6
0
5
10
15
20
25
30
35
40
45
Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12
DPTT
Month
D2 : Problem Definition :
How Much : On load Defect trend ( Test Rig )
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D2 : Problem Definition
How Big : Pareto Diagram of all defects at Test Rig ( Last 6
Months)
42.1
23.6
13.4
2.5 2.4 1.7 0.2 0.0 0.00.010.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
0.05.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
M/c
Drop
Onload Not
lifting
Linkage
fault
Jerking Slow
lifting
Sticky Lifting
not
proper
Main
cover
leak
AxisTitle
Defects at Test Rig
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D2 : Boundary Diagram
Hydraulic
Pump
OIl
flow
sensor
Main
Cover
Coveracces
sory
Draft &
Position
control
lever
Yoke
assly
Lift
Arm
Ram
Arm
Pisto
n
Cylinde
r assly
Linka
ges
Pr. Relief Valve
Dead
Weigh
t
Test Rig machine body DirtyOil tank
Clean
Oil
tank
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Hyd lifton load
Piston , Ram arm&Yoke
LinkagesCylinder Subassly
Test Rig
Torsion spring stiffness not O.K.
Machine body fouling with Ram arm
Contaminated oil
Cam Profile
on ram not ok
Piston Under size
Hydraulic pump malfunctioning
Main cover subassly
Pr. Relief valve settingInternal leakages
Poor Face
roughnessCheck valve
seat bore dia
O/S
Blow Holes/ porosity in cydActuator lever sticky
Cyd. Hole block / missNPT Plug loose / miss
Cylinder main Bore O/SInternal leakage in cylinder
U/L valve stickyC.V sticky
CD of connecting rod seat and piston face
Linings / scratches in main bore
C.V. setting ( 30 Thou )
Safety valve leakF/V sticky / tight
U/L valve hole blockF/V hole blockC.V. hole block
Internal galleries block due to
contaminationBaffle plate loose
Linkage bend
CoverAccessory
Linkage foulingHole interconnected
Blow holes
Hole block
Hole U/S or block
Inlet Hole O/S
Master spline
shift in Ram Arm
Play in Yoke
Connecting Rod& Serr. Shaft
Conn. Rod O/S
or U/S
Spline shift inserr. shaft
U/L valve plug O ring cut
F/valve plug O ring cut
Cylinder face O ring cut
y2 y3y1
y4 y5 y6 y7
Y
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y Factor Causes April May June July August Sept Total
y1 Cylinder sub assly
Cylinder Sub assly changed 8 5 21 21 24 44 123
C.V. setting 0 0 0 2 1 1 4Actuating lever 0 0 1 0 0 0 1
Face O ring cut 0 2 1 0 2 2 7
F.V. valve tight 0 1 9 2 3 6 21
Baffle plate loose 0 0 1 2 1 4
Plug O Ring cut 2 1 0 3 0 4 10
Cylinder dia 90 O/S 0 0 0 0 8 0 8
Spring setting0 0 1 0 0 0 1
y2 Linkages Draft link fouling 1 0 1 0 0 0 2
y3 Cover Acc. Cover acc. Changed 0 0 1 0 0 1 2
y4 Test Rig Pump changed 0 0 0 2 0 2 4
y5 Main cover Sub assly
Main cover hole U/S 0 0 0 0 1 0 1
Seat Change 0 0 1 0 0 2 3
y6 Piston , Ram Arm & Yoke Ram arm changed 0 1 2 0 1 0 4
y7 Conn. Rod & Serr. Shaft 0 0 0 0 0 0 0
Not known 0 4 1 1 2 2 10
Total 11 14 40 33 43 64 205
0.0
20.0
40.0
60.0
80.0
100.0
0
50
100
150
200
Cylinder sub assly Not known Test Rig Main cover Sub
assly
Piston , Ram Arm
& Yoke
Linkages Cover Acc. Conn. Rod & Serr.
Shaft
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S.No Activity Result
1. Check valve replaced No Change
2. Torsion spring changed No change
3. Unload valve O ring changed No change
4. Complete attachment ( including rear plate ,
torsion spring , actuator lever control lever & roller
No change
5. 30 thou setting done again No Change6. Replacement of cylinder Problem solved
Cylinder no :- UF 017 , lift no. 1157 , Normal
Problem : Onload
Date :- 26.09.2012Team :- Mr. Ritesh ( KMC ) , J Sabarwal , L.R. Kaushik , Sajal Verma , Shlvinder Singh (rework opt. ) , S. Rajneesh & Manoj Giri
Other Observations :Contaminations not seen
All plug O rings found O.K.
All valves holes ( C.V. / F.V. / U.V. ) found O.K.
Baffle plate was tightened properly
Cylinder Face O ring found O.K.
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