Download - Sun Rise Qc Torque
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SUN RISE
QUALITY CIRCLETR UNIT
HEELS INDIA LIMITED
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Leader
Member
Facilitator
Member
MemberNagendran. R Kannan.V
Member
Poosadurai.T
TEAM MEMBERS
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Theme:
TO ELIMINATE CUSTOMERCOMPLAINT DUE TO LOW TORQUE
PROJECT START DATE :05.05.2013
PROJECT END DATE :25.08.2013
PROJECT MEETINGS :Mo!"#
NO O$ MEETINGS %ELD :12
ATTENDANCE :85 &
ABOUT OUR SUN RAISE QC
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Step-1 Identifcation O Problem
TypeAMinimum involvement of other Department in Solving Them /Can be solved by the QCC Member itself
Type B - nvolvement of other Department is a ne!essity
Type C "roblems !an be solved #ith Management assistan!e
Sl. No. Problem Descriptrion
A B C
1 Wrong Assembly position P
2 Bolt twist P
3 Bolt nut Lossened Condition P
4 Wrong rim/ Disc assembly P P
Low !or"ue P
# Double wa$ser Assembly P
% Blow &ole / 'orosity P
( Bolt &ole damage P
) *+cess ,un -ut P P
1. Lug inset problem P
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Ranking
1 - Low 2 - Moderate 3 - High
Total Marks Formula = Multiplication (!"!#!$!%!M&
S .No LineMachine /Operation
Identified problem / issues
Ranking Related to
Total marksP ! " S M
1 Assembly Manual Wrong Assembly (Position) 3 1 1 1 1 1 3
2 Assembly Manual Bolt twist 1 2 1 1 1 1 #
3 Assembly ManualBolt nut LossenedCondition
1 2 2 1 1 1 $
4 Assembly ManualWrong rim Disc !ssembly
3 2 1 1 1 1 %
5 Assembly Manual Low tor"e 3 2 3 2 3 1 108
6 Assembly Manual Double w!#ser Assembly 2 3 2 2 1 1 #$
7 Lug Weld Primo Blow $ole Porosity 3 1 2 2 1 1
8 Oters Oters Bolt $ole d!m!ge 1 3 2 1 1 1 %
! Assembly Manual %&cess 'un ut 2 3 2 1 1 1
10 Painting Manual Lug nset *!ri!tion 1 3 2 1 1 1 %
ro'lem categor)*ssem'l related
Step-2 Selection O Problem
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Problem Definition:
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P,- D%N% +$% P'BL%/
RIM
MFGINTERNAL
STORAGE
LUG
WELDED
RIM AND
DISC
ASSEMBLY
DISC
MFG
LUG
WELDING
INTERNAL
STORAGE
LOADING TO
DESPATCDESPATC
Problem !oi"t
CED
PAINTING
PAC#ING
AS S P'C%SS
PC FINIS
PAINTING
CED
PAINTING
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STEP-4 ANALYSIS THE PROBLEM
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IMPORTANCE / EFFECT OF TE PROBLEM
This is a irritating potential customercomplaint at Tractor export assembly
This may also affect other product soWheels India brand name will lost
Wheels may have to be scrapped andreplaced
IMPORTANCE OF TE PROBLEM
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B$ %&i"' (W ) *
Prod%ctio" lo&&+ Re,or-
co&t i"crea&e.
Problem Definition using W ! "
Lo, Tor/%eWAT i& t0e Problem1
Tractor E2!ort a&&embl$WERE doe& t0i&!roblem occ%r1
Rim ) Di&c A&&embl$WEN doe& it occ%r1
WO "otice t0i&
!roblem1
I"&!ector
OW m%c0 i& t0e
&e3erit$1
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B$A% ST&$M%'
TOTAL NO.OF POINTS4*5
-5 Identiying the CausesS.No List o0 c!uses
1 Low !ir pressure
2 Nut 'unner inconsit!ncy
- 3ns4illed oper!tor
5 Bolt 6 Nut t#re!ds worn out
7 $ig#t D
8 Wrong lug welding inset9 Wrong 'im : Disc !ssembly position
; Wrong position o0 bolt : nut
< Wrong lug si=e
1> Wrong bolt : nut !ssembly
11 Wrong rim code m!r4ing
12 Wrong disc code m!r4ing
1- ncorrect Assembly ?&ture
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/!n
/!teri!lsMethods
Machine
CA(S) * )++)CT DA'$AM /+S, B&%) DA'$AM /S,A.A DA'$AM
N PSSBL%CA3S%S @
1-
Various form
depthWrong location ofmarking
Wrong lug welding
Wrong rim code marking
Wrong disc code marking Wrong disc supply
Wrong Lug welded rim supply
Wrong lug
Wrong Lug welded
Rim & isc
assem!ly position
Wrong position
of nut & !olt
Wrong !olt & nutassem!ly
Wrong lug
welding inset
"ntrained person
#ncorrect $ssem!ly fi%ture
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Method +or Considering Causes for alidation
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/!n
/!teri!lsMethods
Machine
CA(S) * )++)CT DA'$AM
Wro"'A&&embl
NO OF
IMPORTANT
CAUSES 46
Wrong Lug welded Rim &
isc assem!ly position
Wrong Lugwelded rimsupply
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STEP 7 w$y w$y analysis
W0$1
W0$1
W0$1
Co%"ter mea&%re
Wrong assem!ly
Wheels offset changed
isc position changed
Wrong isc
A" arra"'eme"t to 7i"d o%t t0e o77&et o7
7la"'e d%e to Wro"' a&&embl$ to be
!ro3ided
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P'BL%//P'%,
/%N+
B%'% A+%'
There was no proision tofind out the wrongassem!ly
$ flag like arrangementproided to find thewrong assem!ly
Step-8 Developing Solution
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ep-9 Foreseeing Probable Resistan
NoR
esista
nce
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Step-10 Trial Implementation
Sl. NoTrial Date
Process /machine /
Detail of thetrial
No. of QtyTrial taken
Qty Accepted QtyRejected
Final result
125.07.2012 to
27.07.2012
ExportAssembly Wheels have
been assembledto
1500 1500 0
P!A "!E#mplemented is
$or%in& in &ood'ondition.
TRIAL ACCEPTEDTRIAL ACCEPTED
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Standardi0ation1. 2 3 ,
(. ) W*AT W*" W* W*E+E W*E) *W
1 Wron& Assembly
+im dis'assemblyo,,set d-e to
$ron& partassembly
/A Export Assembly A-& 2012
A P!A "!E $ithsensin&arran&ements have
been p-t in pla'e toidenti,y the $ron&assembled $heels.
11 Regular Implementation
T0i& PO#A YO#E i& added i" t0e e2i&ti"' PO#A YO#E Ma&ter li&t a"d bei"'
Mo"itored i" o" dail$ ba&i&.
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$ori=ont!l
Deploymentame type o0 system $as been planned toDomestic !ractor Assembly
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p-12 Follow p !"onitoring # Revi
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'D Customer complaints $ae been eliminated in *+portassembly
,ewor due to wrong assembly $as been eliminated5
,ewor operators 0atigue $as been eliminated5
-n time deliery
a0ety issues during o6ine rewor $as been eliminated
Bene7ts
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COST BENEFITS
E2ter"al Sa3i"'&8C%&tomer com!lai"t9
Replacing cost per wheel "'()*+++
Total cost #NR ,-,+-+++
I"ter"al &a3i"'&
Laa!our cost per wheel Rs.,
/onsuma!le cost per person Rs.0
1anpower for rework 2
Total wheels per year *++
Total cost +3++
Total cost saing45ear #NR ,-0+-3++
Total cost for complete the pro#ect
!l "o#t for "om$lete t%i# $ro&e"t'R#()*)+
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THANKS TO ALL