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Reduction of Total
Cost of Quality
CIAMD
COQ
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PROJECT CHARTER
CIAMD
COQ
Project Name * Reduction of Total Cost of Quality
Project Description * Reduction of In-House Machining Rejections & Penalties paid due to Customer Complaints
Champion * NV Devaraj Phone +91 44 2746 6080 Email [email protected] Leader * V sivakumar Phone +91 44 2746 8450 Email [email protected]
Finance champion * Ritanjali Panda Phone +91 44 2746 6080 Email [email protected] Belt * K Karthikeyan Phone +91 44 2746 8450 Email [email protected]
Region * TFC Asia Location * IMSD-India
Priority * Project Type *
Target Start Date * 2-Mar-09 Target End Date * 1-Sep-09
Actual Start Date * 25-Dec-08 Actual End Date * 28-May-09 Budgeted in FY09 (Yes / No) * Yes
Problem Statement * In-house machining Rejection has appreciable scope for improvement.
Customer complaints is high
Project Objectives * Reduction of Total cost of quality thru reduction of In-House Machining Rejections & Penalties paid due to Customer Complaints
Project Benefits * Cost of In-House Machining Rejection & Penalities paid to Customer complaints in Fy08 is 119K. Plan to reduce the cost from 119K to 60K
Please specify the way
how the financial benefits
are calculated
Project Scope * Parts machining in In-House Machine shop & Penalties paid due to customer complaints
In Total Cost of quality, Failure Cost only considered
Comments
Financial Metrics * Hard Soft
Sales Growth Sales Growth
Unit: USD '000 Projected Projected
Committed Committed
Implemented Implemented
GOI Growth GOI Growth
Projected ProjectedCommitted Committed
Implemented Implemented
FCF FCF
Projected Projected
Committed Committed
Implemented Implemented
Sign Off *
Name
Champion NV Devaraj
Belt K Karthikeyan
Entity controller Ritanjali Panda
Entity GM S Prabhakar
Asia HQ
Medium Cost Improvement
OpEx & E2E Project Approval Form
Annualized Realized in FY09 Annualized
60.00 -
Realized in FY09
Project Start - Date & Signature Project Close - Date & Signature Project Implementation - Date & Signature
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TEAM MEMBERS
CIAMD
Role Name
Entity GM S Prabhakar
Champion NV Devaraj
Black Belt K Karthikeyan
Finance Champion Ritanjali Panda/S Prabhakar
Leader V Sivakumar
Team Member S Kannan
Team Member S Arunbabu
Team Member R Ellumalai
Team Member J Murugan
Team Member B Velayudham
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CIAMD
Voice of Customer & Critical To Quality
VOC CTQ Metric
Reduction of TotalCost of Quality
Reduction of In-house MachiningRejections
KUS$
Reduction ofCustomerComplaint Debits
KUS$
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MSAPerformed for Critical Process Parameters in 6 F362 Klok Body
15.15
15.10
15.05
15.00
1
Operators
Measurment
2 3 4 5
Mean
MuraliRajasekar
Thangam
O perators
Gage name: H Shift K lok Body
Date of study: 08/01/09
Reported by : S A runbabu
Tolerance: 0.1
Misc:
Panel variable: Sample
Gage Run Chart of Measurment by Sample, Operators
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MSA
Part-to-PartReprodRepeatGage R&R
400
200
0
Percent
% Contribution
% Study Var
% Tolerance
0.04
0.02
0.00SampleRange
_R=0.00632
UCL=0.01627
LCL=0
Murali Rajasekar Thangam
15.12
15.06
15.00SampleMean
__X=15.0378UCL=15.0443LCL=15.0313
Murali Rajasekar Thangam
54321
15.12
15.06
15.00
Sample
ThangamRajasekarMurali
15.12
15.06
15.00
Operators
54321
15.12
15.06
15.00
Sample
Average
Murali
Rajasekar
Thangam
Operators
Gage name: H-Shift K lok Body
Date of study: 08/01/09
Reported by: S A run babu
Tolerance: 0.1
Misc:
Components of Variation
R Chart by Operators
Xbar Chart by Operators
Measurment by Sample
Measurment by Operators
Operators * Sample Interaction
Gage R&R (ANOVA) for Measurment
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MSA
CIAMD
Gage R&R
%Contribution
Source VarComp (of VarComp)
Total Gage R&R 0.0000391 1.04
Repeatability 0.0000379 1.01Reproducibility 0.0000012 0.03
Operators 0.0000012 0.03
Part-To-Part 0.0037137 98.96
Total Variation 0.0037528 100.00
Process tolerance = 0.1
R&R < 10 % Acceptable
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List of Potential-Xs
Error in Process Data Sheet
Improper Cutting Tools
Improper Jigs & Fixtures
Erratic errors in Machine
Error in change over
Improper Handling of Material
Error in first off inspection report Instrument Error
Incorrect Process parameter
Operator Error
New tool trials
Non availability of measuring instruments/gauges
Error in Tool Presetter
Improper cleaning of Jigs & Fixtures
Inspection method
Error in CNC Program
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Qty 335 321 106 4
Percent 43.7 41.9 13.8 0.5
Cum % 43.7 85.6 99.5 100.0
Product OtherMorin YokeKlok DiscKlok body
800
700
600
500
400
300
200
100
0
100
80
60
40
20
0
Qt
y
Perc
ent
Pareto Chart of Rejections-Mar08-Nov08
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Qty 8 16182 26 25 21 19 16 13 9
Percent 2.4 4.854.3 7.8 7.5 6.3 5.7 4.8 3.9 2.7
Cum % 95.2 100.054.3 62.1 69.6 75.8 81.5 86.3 90.1 92.8
Reasons
Other
Acro
ssflatdepth
Glandbore
T
oppadhole
Seatbore
Oil
Hole
Flangehole
10thReference
Seatface
Stemb
ore
350
300
250
200
150
100
50
0
100
80
60
40
20
0
Qty
Percent
Pareto Chart of Klok Body Rejections
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Qty 860 60 24 9 7 6 4 4
Percent 4.433.0 33.0 13.2 4.9 3.8 3.3 2.2 2.2
Cum % 100.033.0 65.9 79.1 84.1 87.9 91.2 93.4 95.6
Reasons
Other
Poorfinish
Ovality
Ho
rizontalshift
Verticalshift
Damage
Unwash
Oversize
Linemark
200
150
100
50
0
100
80
60
40
20
0
Percent
Pareto Chart of Klok Body Stem Bore
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Stem Bore
Rejections
Causes Effect
Measurements Materials Men
Environment Methods Machines
Error in
Setting
(Tools &
Fixture)
Typo in
PDS
Wrongloading
of Boring
bars
Upward Pallet
Movement in M-I
Y Axis Movement
during power cut
Tool Presetter Error
Cutting chips
accumulation in
Finish Boring Bar
HSS Drills
dragging in
CF8M Body
Incorrect
process
parameters
Non availability
of Dial Gauge
No identification
in gauges
CIAMD
Recommendedtools not used
Tool mark
due to
power cut
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Qty 8 16182 26 25 21 19 16 13 9
Percent 2.4 4.854.3 7.8 7.5 6.3 5.7 4.8 3.9 2.7
Cum % 95.2 100.054.3 62.1 69.6 75.8 81.5 86.3 90.1 92.8
Reasons
Other
Acro
ssflatdepth
Glandbore
T
oppadhole
Seatbore
Oil
Hole
Flangehole
10t
hReference
Seatface
Stemb
ore
350
300
250
200
150
100
50
0
100
80
60
40
20
0
Qty
Percent
Pareto Chart of Klok Body Rejections
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Qty 23 1 1 1
Percent 88.5 3.8 3.8 3.8
Cum % 88.5 92.3 96.2 100.0
Reasons OtherLine markDimensional DeviationDamage
25
20
15
10
5
0
100
80
60
40
20
0
Q
ty
Per
cent
Pareto Chart of Seat Face Rejections
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Seat Face
Damage
Causes Effect
Measurements Materials Men
Environment Methods Machines
Improper Material
Handling
Improper cleaning of
fixtures & jigs
Storage
Method
Improper Material
Handling
CIAMD
COQCause & Effect Diagram
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Qty 335 321 106 4
Percent 43.7 41.9 13.8 0.5
Cum % 43.7 85.6 99.5 100.0
Product OtherMorin YokeKlok DiscKlok body
800
700
600
500
400
300
200
100
0
100
80
60
40
20
0
Qt
y
Perc
ent
Pareto Chart of Rejections-Mar08-Nov08
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Qty 155 102 47 16
Percent 48.4 31.9 14.7 5.0
Cum % 48.4 80.3 95.0 100.0
Disc Reasons OtherStem boreDisc PinningDisc profile
350
300
250
200
150
100
50
0
100
80
60
40
20
0
Pe
rcent
Pareto Chart of Klok Disc Rejections
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Qty 145 10
Percent 93.5 6.5
Cum % 93.5 100.0
Disc Profile Line mark Damage
160
140
120
100
80
60
40
20
0
100
80
60
40
20
0
Q
ty
Per
cent
Pareto Chart of Disc Profile
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Disc Profile
Damage
Causes Effect
Measurements Materials Men
Environment Methods Machines
Improper Material
Handling
Improper cleaning of
fixtures & jigsDamaged Profile
cover
Storage
Method
Fixture designImproper Material
Handling Equipment
CIAMD
Tool mark
due to power
cut
COQCause & Effect Diagram
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Qty 155 102 47 16
Percent 48.4 31.9 14.7 5.0
Cum % 48.4 80.3 95.0 100.0
Disc Reasons OtherStem boreDisc PinningDisc profile
350
300
250
200
150
100
50
0
100
80
60
40
20
0
Pe
rcent
Pareto Chart of Klok Disc Rejections
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Qty 32 11 8 4 2 3
Percent 53.3 18.3 13.3 6.7 3.3 5.0
Cum % 53.3 71.7 85.0 91.7 95.0 100.0
Reasons
Othe
r
DrillBr
oken
Dimensio
nalD
eviatio
n
Damag
e
Horiz
ontalshi
ft
Verticalshi
ft
60
50
40
30
20
10
0
100
80
60
40
20
0
Qty
Percent
Pareto Chart of Disc Pinning Rejections
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Disc pinning
Rejections
Causes Effect
Measurements Materials Men
Environment Methods Machines
Center Height Variation
in SPM II
Drill Grinding angle
Worn-out
Fixtures
Inspection method
variation between
Inspectors
Insufficient
Coolant
DRO Error
Manual Drill
grinding
PDS ErrorImproper
tools
Stem Keyway slot
Stem undersize
Disc bore
oversize
No proper gauge for
Taper checking
CIAMD
No identification
in reamers
COQCause & Effect Diagram
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Klok Body-Stem Bore Rejections
CIAMD
Objective:
Specific Areas to Improve:
Support Team
Current Situation:
Problems to Overcome:
Activity Detailed Specific Actions in SequenceResponsible
person(s)Time Line
Resources
Required
Expected
Outcome/EvidencesDate Result
Process validation of PDS with actual RE 02-02-09 Process Validation Report 02-02-09 1.Bore size is not achieved as
per PDS of 12" Body, because
YKM Finish Boring bar is
mentioned in PDS which is not
running since the tool is not
available.
Process revalidation after procurement of tool RE 10-03-09 Boring Bar Process Validation Report 19-03-09 Completed
1.2.Elimination of line mark due to wrong loading of
boring bar in spindle
Visual display for loading method PN 08-01-09 One Point Lesson 18-02-09 Completed
1.3.Eimination of Rejection due to line mark caused
by upward movement of pallet.
Pallet seal kit to be replacement and observation NG Seal Kit Changed 25-12-08 Completed
1.4.Elimination of Rejection due to Y axis movement
During powercut in Mazak II
UPS Feasibilty to be studied NG TBD UPS required for
4 HMCS. Total
Cost of UPS is
80K
Defered now to avoid capital
expenditure
1.5.Elimination of Rejection due to Line marks caused
by Burr accumulationCombination Boring Eliminated & One additional
BB added for Gland Bore
JM/RE 09-01-09 Process changed & updated
in PDS
17-02-09 Completed
2.1. Elimination Rejection due to Oversize by wrong
Gauge Usage due to no identication on Gauge Guage Identification to be Done for All gauges
S Anandan/
S.Arunbabu
25-12-08 Implemented for all gauges 20-01-09 Completed
2.2.Elimination of Rejection due to oversize due to
Error in presetter Values for different machines
Estabish the list of values to be set in presetter for
individual boring bar.
RE 15-03-09 List displayed to refer and
set for the size required
02-04-09 Completed
2.3. Elimination of Rejection due to Oversize because
of burr inclusion in Finish boring Opn. (in
Combination Boring)
Combination Boring Eliminated & One additional
BB added for Gland Bore
JM/RE 09-01-09 Boring Bar Stem bore line mark
elimination Updated in PDS
17-02-09 Completed
2.4. Elimination of Rejection due to Oversize because
of non usage of bore dial during repass due to non
availability of Bore dial Gauges.
Procurement of Bore Dial Gauges to meet our
requirement
S Anandan/
S.Arunbabu
06-01-09 D ia l gauge - 3
Nos size from
10mm-65mm
Boring bar procured &
implemented
24-04-09 Completed
3. Elimination of Stem bore Unwash due to drag
caused by improper grindingProcurement of "Drill Point Grinder" to ensure
proper grinding
VSK TBD Procurement of
new drill point
grinder - 3K
To avoid investment,
Resharpening arrangement
made with M/s Avenzer
Tools up to the procurement
of "Drill Point Grinder"
23-01-09 Completed
4.Elimination of Stembore Damage by burr inclusion
during loading of ComponentsOne point lesson is to be displayed
PN 07-01-09 One Point Lesson Displayed
in Workstation
17-02-09 Completed
Comments:
Signatures of Support Team
1.1.Elimination of Line mark rejection due to non
compliance of PDS parameters and tools
V.Sivakumar
Signature of Originator
54.3% of Rejection of K Lok Body Rejection of 43.7 % (23.7% of Total Rejection) was due to stem bore rejection during FY08
-
Implementation Evaluation
Reduce In house Machining Rejection
To reduce Rejection due to stem bore rejection
N Gobi, R Elumalai,P Nirmal raj, J Murugan, B Velayutham, TK Murali, S Anandan, S Arunbabau
ACTION PLAN
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CIAMD
Objective: Date: 2/2/09
Specific Areas to Improve:
Support Team
Current Situation:
Problems to Overcome:
Activity Detailed Specific Actions in Sequence Responsibleperson(s)
Time Line ResourcesRequired
ExpectedOutcome/Evidences
Date Result
1.Validating the process of 12"370 G1 K LOK Body as
per PDS
Process validation RE 02-02-09 Process Validation Report 02-02-09 1.Bore size is not achieved as
per PDS, because YKM Finish
Boring bar is mentioned in
PDS which is not running
since the tool is not available.
2.Combination rough boring
new insert Grinding and Shim
packing because insert
clearnce is not given(Tool
Design mistake)
3.Program Seqence is
mismatch
4.WCMX 080412 1020
GRADE Stock nill(old stock
insert runing)
2.Purchase of Finish boring bar 2.1.Tool Design RE 05-02-09 Tool Dwg No KHT 214 05-02-09 Completed
2.2.PR Creation RE 05-02-09 PR No 9040000207 05-02-09 Completed
2.3.PO Creation TKM PO No 9030000737 13-02-09 Completed
2.4.Tool Purchase TKM 09-03-09 Mat Doc # 5000007437 05-03-09 Completed
2.5.Tool inspection RE 10-03-09 Completed
3.Purchase of Combination Rough boring bar 3.1.Tool Design RE 23-01-09 Tool Dwg No KHT 241 23-01-09 Completed
3.2.PR Creation RE 06-02-09 PR No 9040000195 06-02-09 Completed
3.3.PO Creation TKM PO No 9030000710 13-02-09 Completed
3.4.Tool Purchase TKM Mat Doc # 5000007672 13-03-09 Completed
3.5.Tool inspection RE 19-03-09 Completed
4.Program Seqence mismatch 4.1.Program to be modified RE 06-02-09 Cadem Prg , 06-02-09 Completed
4.2. PDS Revision RE 10-02-09 PDS-0036-30-Rev2 10-02-09 Completed
5.WCMX 080412 1020 GRADE prequre 5.1. Maintaing Stock Level at store Paranthaman
Non moving insert WCMX
08 04 12 R53 4025 is being
used.Qty 10 as on 2/4/096.Process Revalidation Process validation RE 10-03-09 Bore Dial Gauge Process Validation Report 19-03-09 Completed
Comments:
Signatures of Support TeamSignature of Originator
Evaluation
Approval on Tool Inspection can be only justified after taking trial
Implementation
Process validation result found satisfactory. 36+11 nos in Job 0rder # 3437 & 3259 are prodcued without line mark. After
Consumption of WCMX 080412 R53 4025, Insert as per PDS (ie. WCMX 080412 1020) will be made stockV.Sivakumar
ACTION PLAN
Boresize not achieved when cutting parameters are maintained as per PDS for 10" &12" G1 Body
TK Murali, Arunbabu, M.Madhavraja, Paranthaman.R Elumalai,
To reduce Rejection due to Line mark in Stem bore- in K Lok Body Machining in 30th Opn.
Reduce In house Machining Rejection
Klok Body-Stem Bore Rejections COQ
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CIAMD
Klok Body-Stem Bore Rejections COQ
Objective: Date: 4/2/09
Specific Areas to Improve:
Support Team
Current Situation:
Problems to Overcome:
Activity Detailed Specific Actions in SequenceResponsible
person(s)Time Line
Resources
Required
Expected
Outcome/EvidencesDate Result
1.Estabish the list of values to be set in presetter forindividual boring bar.
1.1 Preparation of list of Sizes of Boring bars usedin KIA,Mazak I & Mazak II
RE 04-02-09
List of Boring Bars for all
sizes prepared for Kia, M-I,
& M-II
04-02-09 Completed. 36 Sizes /eachmachine identified,
1.2. Collection of data for list given whenever doing
settingRE 15-03-09
Actual Values against
Boring Bar Sizes Required02-04-09 Completed.
1.3.Compensation value arrived for the above
boring barsRE 15-03-09
First Time Right in Bore
sizes during setting02-04-09 Completed
2. Presetter Runout (0.06) to be rectified 2.2. Finding the root cause &Salvaging the problem RE 03-04-09 Ridges found in BT 50Taper corrected
03-01-09 Completed
Comments:
Signatures of Support Team Signature of Originator
Evaluation
Due to the above reason variation with Presetter value and Actual bore size . This variation varies with Tool length and Machine. Same tool produce different dimension when
interchange between workcenters
Implementation
V.Sivakumar
ACTION PLAN
Lack of confidence in applying compensation for tools in Tool Pre Setter and lead first job rejection during setting
M Madhavaraja,J Murugan,B Velayutham
To reduce Rejection due to Oversize in Stem bore- in K Lok Body Machining in 30th Opn.
Reduce In house Machining Rejection
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CIAMD
Klok Body Rejections Trend COQ
Klok Body Rejections
0
20
40
60
80
100
120
May-08
Jun-08
Jul-08
Aug-08
Sep-08
Oct-08
Nov-08
Dec-08
Jan-09
Feb-09
Mar-09
Apr-09
May-09
Qty(Nos.)
Stem bore
Total Body
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CIAMD
COQKlok Disc Profile Damage Rejections
Objective: Date: 2/2/09
Specific Areas to Improve:
Support Team
Current Situation:
Problems to Overcome:
Activity Detailed Specific Actions in Sequence Responsibleperson(s)
Time Line ResourcesRequired
ExpectedOutcome/Evidences
Date Result
1.Elimination of rejection due to Loading of
Component in fixture with burr
Operator Training JM On going - One Point Lesson 17-02-09
Elimination of Material Handiling without
protector.
MM/JM/BV On going - OJT provided to Operators
& Material Handlers
17-02-09
Removal of Wornout & damaged end caps JM/BV On going Replacement of
wornout endcaps
scrap wornout & damaged
end caps
26-05-09
Comments:
Signatures of Support Team
K Karthikeyan,J Madhvaraja, A K Ravichandran TK Murali,Arunbabu
To reduce Rejection due to Disc Profile Damage
Reduce In house Machining Rejection
ACTION PLAN
48.4% of Rejection of K Lok Disc Rejection of 41.9 % (20.27% of Total Rejection) is due to Disc profile Damage
2.Elimination of Rejection due to improper Material
Handling
Signature of Originator
Evaluation
Training of material handlers & trainee operators
Implementation
V.Sivakumar
Rejection due to profile
damage drastically reduced
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Klok Disc Profile Rejection Trend
CIAMD
COQ
Klok Disc Rejections
0
10
20
30
40
50
60
May-08
Jun-08
Jul-08
Aug-08
Sep-08
Oct-08
Nov-08
Dec-08
Jan-09
Feb-09
Mar-09
Apr-09
May-09
Qty(Nos.)
Profile Damage
Total Disc
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CIAMD
COQKlok Disc Pinning Rejections
Objective: Date: 28/01/2009
Specific Areas to Improve:
Support Team
Current Situation:
Problems to Overcome:
Activity Detailed Specific Actions in SequenceResponsible
person(s)Time Line
Resources
Required
Expected
Outcome/EvidencesDate Result
1. Elimination of Rejection due to Centre Ht. Variation
of Both SPM I &II
Both Machines are made to Same Ht. NG 22-01-09 Same Fixture Can be used
in both machines
24-01-09 Completed
2. Elimination of Rejection due to difficult checking
method by using Pin Implementation Taper Gauge.
SAB 27-03-09 Gauge Taper gauge which is easy
to check in online
03-04-09 Completed for 4"Fig 370 &
horizontal deployment to other
sizes
3.Elimination of rejection due Manual Grinding
leading to Drill Drag
Drill Point Grinder is to be implemented to avoid
manual grinding
VSK 09-06-09 Procurement of
new drill point
grinder - 3K
Elimination of Manual
Grinding
23-01-09
To avoid investment,
Resharpening arrangement
made with M/s Avenzer Tools
up to the procurement of "Drill
Point Grinder"
4. Avoid usage of tools without identification & tools
mixup
Separate tool location are provided to avoid tools
mixup. Part number engraving on tools
JM 04-02-09 Part Number engraved on
Tools. Separate tools
location provided
04-02-09 Completed
Replacement of worn out parts in fixtures PN 27-02-09 Reconditioned fixtures 05-05-09 Replacement of individual
parts does not produced the
desired result.
New Fixture Design & Development RE 05-08-09 New Fixtures for 8 sizes 4" Fixture procurement willcomplete in june 3rd week Design Completed &procurement action inprogress
for 4" fixture
Validation of all new Pinning Fixtures RE 28-08-09 New Fixtures for
8 sizes
Completion of all Fixture
validation
Comments:
Signatures of Support Team
31.9% of Rejection of K Lok Disc Rejection of 41.9 % (13.36% of Total Rejection) is due to Disc pinning Rejection
5.Elimination of Rejection due to Wornout Fixtures
Signature of Originator
Evaluation
Disc Pinning Fixtures recondition
Implementation
V.Sivakumar
P.Nirmal Raj, R Elumamalai, J Murugan, B Velayutham TK Murali, Ananadan,Arunbabu
To reduce Rejection due to Disc pinning Operation
Reduce In house Machining Rejection
ACTION PLAN
COQ
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Customer ComplaintsCOQ
Customer Complaint Debit
0
1000
2000
3000
4000
5000
6000
7000
8000
Casting Packing Machining
USD
Value
Note: All Non Conformance debit from slurry product line only
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Customer ComplaintsCOQ
Objective:
Specific Areas to Improve:
Support Team
Current Situation:
Problems to Overcome:
Activity Detailed Specific Actions in SequenceResponsible
person(s)
Resources
Required
Expected
Outcome/EvidencesDate Result
1. Existing stock to be send to foundry for inspection Radiography test to be done in foundry & repair ifneeded
SK/PMR/TS - Casting free from nonconformance Feb-09
2. Improve the quality of castingsAction plan to get the quality castings from the
existing foundriesSK/PMR/TS - - Jan-09
No support from the foudry to
improve the quality of castings
3. Develop New FoundriesDevelop New foundry and shift tyco patterns from
existing foundry without affecting productionNVD/TM/PMR -
Development of new
suppliersApr-09
In Phase-1 Seven patterns
shifted & developed at new
source. In Phase -2 twenty
patterns shifted to new
foundries. Phase-3 in
progress for 23 Patterns
Comments:
Signatures of Support Team
Casting failure at customer end in NDT
Signature of Originator
Evaluation
Casting failures in Slurry valves from 3 key foundries
Implementation
NV Devaraj
NV Devaraj, S Kannan, P Mohan Rangan, T senthil, T Murugan
Supply of the Castings to be improved
ACTION PLAN
To reduce Non conformance Complaint from customers
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Customer ComplaintsCOQ
Packing
Implementation of End covers to avoid serration damages at all stagesincluding from supplier end, transit and packing of FG
MachiningSupplier audit done for machining process & Measuring instruments
Implementation of one point lessons at supplier end
To avoid further customer complaints, critical parameters are re-inspected for
the components in stock, which is machined at supplier.
Supplier rationalization is in progress to avoid continuous quality issues
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In-house Machining Rejection TrendCOQ
1.52%
0.77%
2.09%
1.19%
0.74%
1.63%
1.52%
0.82%0.67%
0.00%
0.50%
1.00%
1.50%
2.00%
2.50%
FY-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09 May-09
FY-08 Inhouse Rejection %
Project
Initiated in
Jan-09
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Customer ComplaintsCOQ
8.2
1.30.7
4.4
0.0 0.0
0.0
10.0
24.724.724.7
20.3
8.2
18.3 19.6
8.2
0.0
5.0
10.0
15.0
20.0
25.0
30.0
Oct'08 Nov'08 Dec'08 Jan'09 Feb'09 Mar'09 Apr'09 May'09 Jun'09 Jul'09 Aug'09 Sep'09
NCR Debit Value KUS$ Cumulative FY09 KUS$
Project
Initiated in
Jan-09
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Cost of Quality TrendCOQ
9,7849951
3,304
1,701
6,293
5,546
0
2000
4000
6000
8000
10000
12000
FY-08 Monthly
Avg
Jan-09 Feb-09 Mar-09 Apr-09 May-09
Valuein
US
FY-08
COQ
Project Initiated
in Jan-09
COQC l M f I h
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COQ
Control Measures Responsibility
Daily Review of In-house machining rejections VS
Random Process Audit at in-house machine shop RE / SAB
Revalidation of Fixtures RE
Monitoring Standard cycle time (Noted in PDS) to ensure
process parameters are not altered
JM
Ensuring all CNC programs downloaded from DNC JM
Replacement of all worn out Protective Covers / End Caps BV
Training of new employees VS & Team
Control Measures for In-houseMachining Rejections
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COQ
Control Measures for Customer Complaints
Control Measures Responsibility
Customer Complaints Review & Effective CAPA SK & PLMs
Ensure Periodic process audit at both suppliers & in-house SK & Team
Strengthen Development of New Products QM & Buyers
Strengthen Development of New Suppliers QM & Buyers