Sl no. Inspection parameters Specification Observations Results1 Mounting Holes C.D OK O2 Pattern not OK Various elements OK O3 Poor fettling Extra material OK O4 Multi Cavity Varriation Profile and radius Profile not ok & undersize X

Multi Cavity Varriation Profile and radius No fouling during assly. OKVerification after Gauge introduced

Sl no. Inspection parameters Specification Observations Results1 Mounting Holes C.D OK O2 Pattern not OK Various elements OK O3 Poor fettling Extra material OK O4 Multi Cavity Varriation Profile and radius Profile not ok & undersize X

Multi Cavity Varriation Profile and radius No fouling during assly. OKVerification after Gauge introduced

Target

Nov'11 24Dev'11 18Jan'12 10Feb'12 0

Why. Machining ShiftWhy. Pattern Not okWhy. Poor fettlingWhy. Multi cavity varriation Why.

Nov'11 Dev'11 Jan'12 Feb'120

5

10

15

20

25

30

24

18

10

0

Nov'11 Dev'11 Jan'12 Feb'120

5

10

15

20

25

30

24

18

10

0

Department/MBU Quality

Machine/Line : Engine LinePlant: NHFIPL Project Code

Theme : To resolve Water pmp support fouling during engine assly. Part no.4840211 Cost Center 613

ROOT CAUSES

Descprition of the phenomenon ( 5W-1H)

Problem - Fouling during assly.( Water Pump Support- Supplier Versatile)

What - Water Pump Support Fouling with Gear Case.

When -

Where - At Engine assly.station-5

Who - assly. Associate

Which - Randomly

How -

1) Reciever Gauge added in calibration plan.

2) Pattern Life Defined and Monitored.

Tools used:4M 5W1H AM Tag FMEA NVAA Poka Yoke QM Matrix SMED X Matrix5S 5why ABC Class. Kanban OPL QA matrix Six Sigma VSM Others

Project leader Starting Date: Implementation team: Completion Date: Costs: Benefits Results: Benefit/Cost Verification:

Mahender Pathak 1 Dec 2011 Yogesh Kumar, Rambir Kadian 1-Feb-12 4264 66440 62,176 15::1 Ok

2) Receiver Gauge introduced for fouling to improve detection at supplier end. From 20/01/2012

During water pump support sub assly.with Engine block on 5th Nov 2011 in A-Shift

Water pump support not sitting properly for the assembly leading to the loss of 52 tractors

Revised Phenomenon

Water pump support fouling with Gear Case during sub assembly with engine block at station - 5 observed by Assembly associate occuring randomly leading to the loss of 52 trators

TARGET

10hPLANPLAN DODO

CHECKCHECKACTACT

PLANPLAN

STANDARD KAIZEN / PDCA(Chronical Problems)

Fouling Locations

Water pump support fouling with Gear Case during sub assembly with engine

block at station - 5 observed by Assembly associate occuring randomly

leading to the loss of 52 trators

MAN Machine

MethodMaterial

Unskilled Manpower Not ApplicableFitment

Orientation opposite

Process Sequence Wrong

Support Mounting hole CD not ok

CD of Engine Block Not Ok

Excess Parting Line in gear Case

Poor Fettling in Water Pump Support

Outer profile not ok

Zero Defect

"LH and RH"R11 fouling area. Correction done in pattern & also machinig cut added on the castings.

Containment Action:- 1) Available Stock Segregated with Support of Mockup assembly of Engine ok part supplied on the line.

Permanent Corrective Action:-

NOT APPLICABLE TO EEM/EPMAPPLICABLE TO EEMAPPLICABLE TO EPM

SAF(Safety)

WO(Workplace Organization)AM(Autonomous Maintenance)

PM(Professional Maintenance)

QC(Quality Control)L&CS(Logistics & Customer Service)

EEM(Early Equipment Management) PD(People Development)ENV(Environment)CD(Cost Deployment)

FI(Focused Improvement)EPM(Early Product Management)

Water pump Support Fouling with Gear Case

Outer radius profile Not

Ok

Cavity not ok

Multi Cavity Variation Pattern not Ok

Why -1 Why - 2 Why - 3

Why Why Analysis

Water pump Support Fouling with Gear Case

No Inspection for Casting

profile

No Reciever gauge Not Required for Casting Profile

Pattern not Ok

Why - 4

Why Why AnalysisWhy - 5

No validation for Fitment during

multi Cavity usage

Not Required for Casting Profile