quality innovation plan

• Date : 2 Jan’14

• Reporter : Vinit Chaudhary

• Deptt : Quality

Agenda Talking Point (Discussion / Decision)

Presentation Time Spend Time

Quality Innovation Plan 2014

Leaders have to Listen 70% and suggest Opinion 30%Let’s Make a Suggestion but Don’t Blame on Other OpinionTime Is Money

MeetingRule

1. 2013 Q. Result & Review of innovation activities2. 2014 Target & action Task3. 2014 Investment plan -Appendix. - Analysis of quality KPI Issue trend &

Achievement target - Appendix Action plan quality KPI wise - Detail investment plan sheet

2 Hours 30 Minutes

•FFR To be improve through innovation and best practice implementation.•All the activities done for FFR improvement to be follow regularly.•To reduce the process issues , self/Sequential Checkpoint to be monitor by Quality Inspector on line.

2013 Quality Innovation Review Process defect Rate

Process defect Rate(PPM)

Good Point

Weak Point

Review 2013

1. PCB Rejection / Functional Issue Reduce .2. Out case gap improvement.3. HVT Rejection Reduce .4. Carton Box Moisture Issue end.5. Accessory Missing issue Reduce.6. Appearance issue detection increase.7. Rotating Ring Broken Issue decrease.

1. Harness Wire Issue Increase2. Door High Leakage issue increase.3. Door Melt Issue in 20 Ltr .4. Choke cover melt rej. Increase in 20 ltr. Model.5. 30 Ltr. Chamber fan touching .motor bracket issue.6. Convection & grill model oil fume not control.7. 30 Ltr. Convection heater IR fail rej. increase.8. Lamp fuse rej. Increase .9. Suction Fan Extra Noise Issue Increase .10. Magnetron rej. Increase.

23541

Y’12

1459038%↓

Total PPM

Process PPM

Part PPM

Y’13

15114

Y’12

10831

7444

Y’12

3829

Y’13

Y’13

28%↓

48%↓

Process defect Rate2013 Target & Task of key action

Process

1) Choke Cover Melt 20L

Current Target Tool Deptt Start End

0.08 0.06 DI Material 14’01 14’03

0.04 0.03 DI Material 14’01 14’03

0.04 0.03 DI Material 14’01 14’03

0.04 0.03 DI Material 14’01 14’03

0.04 0.03 DI Material 14’01 14’03

0.04 0.03 DI Material 14’01 14’01

0.03 0.02 DI Material 14’01 14’03

1 Level 2 Level 3 level

Design

Part

2) MWO Dead

1) Door Melt 2) Door High Leakage 3) Connector Open

1) No Issue

PDR

20%↓

`13Result

`14.Target

14590ED

Total

0.74%

0.38%

0%

4) Lamp Fuse

6) Heater Sheath IR Fail

5) Micro Mode No Power Consumption

Current Target Tool Deptt Start End

0.12 0.096 Task /DI Prod 14’01 14’03

0.03 0.024 Task /DI Prod 14’01 14’03

0.02 0.016 Task /DI Prod 14’01 14’03

0.01 0.008 Task /DI Prod 14’01 14’03

0.01 0.008 Task /DI QA 14’01 14’03

11771

3) Door Paint NG

7) Suction Fan Extra Noise

4) MWO Dead 5) Chamber Fan Extra Noise

PDR Improvement Action Plan Door Melt

Door Melt

2013(R) 2014(Tgt)

20%

0.12%0.096 %

Action Plan Tool Schedule DepttResp

Latching Issue ( 0.11 0.09Cavity Embossing issue ( 0.01 0.008 )

Special Checkpoints

• Cavity Front Plate Flatness Check

• Door Gap check on latching

• Door & cavity temp. check.

• Curling Gap in 32 Ltr.

Defect Detail

MP

Test Std

Parts

1. Door & cavity gap maintain 0.4mm by Jig.2. Door & Front plate Temp. check in LQC to ensure

latching Process3. Cavity Front Plate Flatness

Verification.4. Curling Gap Inspection

starts in LQC .

1. Embossing Height Inspection start in SQA.

2. Curling Gap inspection start in SQA.

1. Door & Front plate Temp. <90˚C. 2. Curling Gap < 0.2mm

3. Front Plate Flatness < 0.5mm

14’01

14’01

14’01

C.P Singh

Vijay

C.P Singh

Prod

Prod

QA

14’02 Vijay QA

DI

14’01

14’02

Amit

Amit

SQA

SQA

14’01

14’02

14’02

Vijay QA

Vijay QA

C.P Singh QA

DI

DI

DI

DI

DI

DI

DI

DI

PDR Improvement Action Plan MWO High Leakage

MWO High Leakage

2013(R) 2014(Tgt)

20%

0.03%0.024

Action Plan Tool Schedule DepttRespMetal Frame Fin Bend ( 0.01 0.008 )Latching NG( 0.02 0.016 )

Special Checkpoints

• Grill Bar Fitment Direction in 32 Ltr.

• Door Metal Frame Fins Alignment.

• Door and Cavity Gap should be maintain and uniform .

Defect Detail

MP

Test Std

Parts

1. Door & cavity gap maintain 0.4mm by Jig.

2. Door Metal Frame Fin Uniformity inspection .

3. Fool Proof Jig for avoid Grill Bar Reverse Fix.

1. Door Metal Frame Fin Alignment.

1. 100% Grill Bar Inspection in LQC.2. Cavity Front Plate and Door Gap Uniformity.

14’01

14’01

C.P Singh

C.P Singh

Prod

Prod

14’02

DI

14’01 Amit SQA

14’02

14’01

Vijay QA

C.P Singh Prod

C.P Singh Prod

DI

DI

DI

DI

DI

PDR Improvement Action Plan Connector Open/Loose

Connector Open/Loose

2013(R) 2014 (Tgt )

20%

0.02%0.016%

Action Plan Tool Schedule DepttRespT.T Motor Connector OpenMain Supply Connector Open

Special Checkpoints

• Connector Should be Press Properly.

• No stress allowed on wires.

Defect Detail

MP

Test Std

Parts

1. Training to Wiring Operators regular bases.

2. Two person for Connector verification.

3. Connector Operator Cross Verification .

4. Operator Skill Verification check sheet .

5. Connector verification check sheet in OQA.

1. TPA Added at Main Supply Connector.

1. 100% connector verification as per below mention process. Pull connector to hold wire Press Connector Inside move to other connector

14’01 C.P Singh

Vijay

Prod

QA

DI

DI 14’01 Mr. Kamaljeet

DI 14’01Vijay QA

Vinit QA

DI

DI

DI

DI

Vijay QA

14’01~14’03 C.P Singh Prod

Material

14’01~14’03

14’01~14’03

14’01~14’03

PDR Improvement Action Plan MWO Dead

MWO Dead

2013(R) 2014 (Tgt )

20%

0.01%0.008%

Action Plan Tool Schedule DepttRespMicro Switch Not Press ( 0.009 0.007 )Fuse Defected ( 0.001 0 )

Special Checkpoints

• Latch Board screw should not be free .

• Micro Switch To Be press completely .

Defect Detail

MP

Test Std

Parts

1. Latching Operators to be fix

2. Holder Locker Screw tight after latching with Electrical gun.

3. 100% Door open/close test in LQC.

4. Fuse 100% electrical inspection in input.

1. Door Latch Should not be warp .

2. Micro Switch Assembled at Supplier end.

1. Latch Board Screw Torque to be > 15 kgf-cm2 2. Micro Switch Should be press completely after Door open/Close operation.3. No deformation allowed in Holder Locker After ELT.

14’01

14’01

C.P Singh

Vijay

Prod

QA

DI

DI 14’01 Mr. Kamaljeet

DI 14’01 Vijay QA

DI

DI

DI

14’01 Vijay QA

14’01 C.P Singh Prod

MaterialDI 14’01

DI

DI

14’01

14’01

Vijay QA

Rakesh QA

PDR Improvement Action Plan Convection fan touching noise

Convection fan touching noise

2013(R) 2014(Tgt)

20%

0.01%0.008%


Fan Bubbling / Alignment NGBoss eccentric .0.01% 0.008%

Special Check Point

• Motor bracket hole CD should be match with Motor CD

• No burr Allowed at Motor Bracket Hole.

• Fan Flatness Should be OK .

• No Ring Washer Required Under Boss .

Defect Detail

MP

Test Std

Parts

1. 100% fan flatness inspection in input.

2. Jig introduced to do centric fitment of motor bracket.

3. Fan Fixing Method Change to stop fan bubbling.

1. Motor Bracket New Tool Provided to ADITYA Auto.2. Motor bracket hole ID reduced to reduce the Play between motor bracket and chamber.

1. Sound Amplifier System Introduce in FQC to Detect Minor Sounds also.

14’01 C.P Singh ProdDI

13’08DI

14’02DI

C.P Singh

C.P Singh

Prod

Prod

13’11DIADITYA Auto Tooling

13’10DI Karan Garg

R&D

14’03DI Vinit QA

PDR Improvement Action Plan Door Paint NG and Scratch

Door Paint NG and Scratch

2013(R) 2014(Tgt)

20%

0.04%0.03%

Action Plan Tool Schedule DepttResp Packing issues0.04% 0.03%

Special Check Point

1. Only one door should be in single block of box .

2. Transportation from E-Vision to E-Durables through Folk lifter instead of Hand lifter.

3. Trolleys made for painted panel .

Defect Detail

MP

Test Std

Parts

1. Packing improved like import door. 2. Only one door placing in one block of box.3. Transportation from E-Vision to E-durables through folk lifter instead of hand lifter.4. 100% door checking in input for scratch and paint NG.

1. Packing improved to avoid transportation issues.2. SQA inspection enhance S2/1.5 G1/0.64

1. 100% door checking in input.

2. Sampling in SQA , G1/0.64

13’11 E-Vision ProdDI


14’01 E-Vision LogisticDI



14’01 Vinit QADI


14’01 Vinit QADI

PDR Improvement Action Plan Choke Cover Melt

Choke Cover Melt

2013(R) 2014(Tgt)

20%

0.08%0.06%

Action Plan Tool Schedule DepttRespMetal Frame Fin Bend0.08% 0.06%Grill Bar Reverse Fix .

New Model Check point

• 100% inspection of door for metal Frame Fin Bend.

Defect Detail

MP

Test Std

Parts

1. Choke Cover Temperature Inspection in LQC for start 30 MWO .2. In repairing MWO For Choke Cover Melt , Operator will verify the Fins alignment .

1. Import Door SQA Inspection Start.2. Supplier Counteraction taken

1. Metal Frame Fin Alignment Inspection.



14’01 Vinit QADI

13’12 Vinit QADI

14’01 Vinit QADI

PDR Improvement Action Plan Lamp Fuse

Lamp Fuse

2013(R) 2014(Tgt)

20%

0.04%0.03


Part Defected0.04% 0.03%

Special Check point

• . 100% Lamp checking with Tesla jig for crack and Vacuum.

• 100% Lamp visually checking for filament loose and crack issue.

• 100% Lamp electrical testing on jig.

• Lamp Transportation via Separate vehicle to improve handling.

Defect Detail

MP

Test Std

Parts

1. Electrical Testing standard revised . Before : 1 Min on 1 Min Cool PackAfter : 1 Min on 5 Min Cool Pack2. Lamp Handling improved.

1. 100% Lamp checking with Tesla jig for crack and Vacuum.2. 100% Lamp visual inspection and Electrical testing started.

1. Lamp Packing improved for reduce crack issue.

DI 14’01 Vinit QA

DI 14’01 Ashu Store

PDR Improvement Action Plan Micro Mode No Power Consumption

Micro Mode No Power Consumption

2013(R) 2014(Tgt)

20%

0.04%0.03

Action Plan Tool Schedule DepttRespMGT 0.018 % 0.014%PCB 0.009 % 0.007 %Diode 0.003 % 0.002 %

Special Check point

• 100% PCB functional Inspection in input.

• Diode Protector Fuse Installed .

• ICTS Testing

• ELT Testing.

• MGT should not be damage .

• MGT Connector should be properly fixed.

• Diode Protector Fuse Rating.

Defect Detail

MP

Test Std

Parts

1. MGT Fixing stage shift after MWO balancing stage to avoid Jerking.2. Electrical gun using at MGT Fixing .3. 100% PCB Functional inspection in Input

1. Magnetron Specification enhance 2M214 2M2462. Diode Protector Fuse implemented .

1. HVT ICTS test , One from Each E.T.D.2. Monthly Reliability of HVT and PCB .




13’10 Mr. Sanjay QADI

13’10 Mr. Sanjay QADI

13’05 Vinit QADI

13’01 Vinit QADI

MGT Defected ( Micro Mode No Power Consumption )

Issue.

Breakthrough Add Life Cycle test to check Part reliability.

Test Condition:-Sample: 08

Test Duration: 830Hrs.

System Change

Result 2014

Anode Temp OKVoltage Cycle Test OKLife Cycle OKELT OK

Validation

MGT (0.018% 0.014%)

Contribution in Micro Mode No Power Consumption : 40%

2013 Failure Status :

Total Defects :27

Production : 147486

Rejection PPM : 183

Cause :Running part has no design margin available i.e operating at 100% Efficiency.

Due to less margin part give reliability Issue and fail itself

Main Issue:-

1.Magnet Crack

2.Anode Cap burn

2013 2014

21

183

HVD Defected ( Micro Mode No Power Consumption )

Issue.

Breakthrough

ON / OFF Limit Test to check the part Sustainability.

Test Condition:-Main AC increase and Micro Mode ON/OFF (Comparison)

System Change

Result 2014

ON / OFF Test OKELT OKLife Test OKSpike Test OK

Validation

HVD Assembly 0.003% 0.002 %

Contribution in Micro Mode No Power Consumption : 10 %


Total Defects :1

Production : 147486

Rejection PPM : 6

Issue

Protector Short

HV Protector change to HV fuse To reduce its failure at higher Voltages

HV Fuse

2013 2014

06

PDR Improvement Action Plan PCB Failure

PCB Failure

2013(R) 2014(Tgt)

20%

0.009%0.007


Part Defected0.009% 0.007%

New Model Check point

• 100% Controller checking in SQA/Input with the help of jig.

• Wristband should be available at all stages of wiring.

• All defects sharing with LGETA .

Defect Detail

MP

Test Std

Parts

1. 100% Controller using on line after verification of SQA.2. On line wristband tester introduce to avoid ESD failure.3. Wristband provide to All PCB wiring operator.

1. Share the defect with the works, and pay attention to the delivery process: a: IMD, SMT, handing insert， EMS movement b: ICT 、 FCT inspection C: Repair unit

2. Relay, VFD a: Defect collection, and send back to manufacture for analysis and improvement b:defect rate control:

1. Monthly Reliability of PCB .

13’07 Prakash QADI

13’06 Chetna ProdDI


13’12 Mr. Rajendra

DI Material


DI Material

13’01 VinitDI QA

PDR Improvement Action Plan MWO Dead

MWO Dead

2013(R) 2014 (Tgt )

20%

0.04%0.03%

Action Plan Tool Schedule DepttRespPCB ( 0.013% 0.010% )Harness ( 0.012 % 0.009%)Holder Locker( 0.004 % 0.003%)Diode ( 0.002% 0.001%)

Special Checkpoints

• Wire Harness Main Connector Should not be open.

• Micro Switch Lock Should Not Be Broken.

• PCB Inspection Marking Should be Available.

Defect Detail

MP

Test Std

Parts

1. 100% PCB inspection start in SQA/Input.

2. Latch Board Screw re-tight by electrical gun after latching.

3. 100% Marking on latch board switch lock in 32 ltr.

4. 100% Harness Main Connector open/loose inspection .

1. PCB Fuse and Diode Quality improved.

2. Micro Switch Assembled at Supplier end.

3. Latch Board material change soft to hard.

4. Diode Protector Fuse Implemented

5. TPA Added in main connector harness.

1. Latch Board Screw Torque to be > 15 kgf-cm2.

13’07

14’01

Prakash ProdDI

DI 13’11 R&D

DI

DI

DI

14’01

14’01 C.P Singh Prod

Material

DI 13’12

DI 14’01 Vijay QA

DI 14’02

DI 13’10

DI 13’11

Mr. Rajendra

Mr. Karan R&D

Mr. Nishant

Mr. Sanjay QA

MaterialMr. Rajendra

C.P Singh Prod

C.P Singh Prod

PCB Failure Issue

Issue.

BreakthroughPower ON/OFF test for New PCB Design

Test Condition:-AC input up to 500V and ON/OFFUnit (Comparison Test)

System Change

Result 2014

Spike Test OKVoltage Cycle OKON / OFF Test OK

Validation

PCB (0.013% 0.010%)

Contribution in Micro Mode No Power Consumption : 10 %


Total Defects :20

Production : 147486

Rejection PPM : 135

Main Issue:-

1.No Power

2.Cleaning

No Power Improvement

1. Fuse change to PTC

20L / 32L

Cleaning Issue:

Conformal Coating Applied

(20L / 21L / 28L / 32L)

2. Bridge Diode change to Discrete

(Vrrm Specs change 600 to 1000V)

20L / 32L

Issue Cause / Analysis Schedule Issue

Door switch Drop (soft lock)

Logic Tree Analysis Improvement Door switch Adjust (soft lock)Model : 32 Ltr convection

Sof

t loc

k is

sue

POM is soft and self lubricating material

it leads to improper switch operation in field

Conclusion

While repeated forcefully Opening and closing the door , switch fixing area becomes weak

Due to repeated pressing the switch fixing area further reduces in strength

Currently using latch board with POM material

NEED to develop latch board with hard material such as PBT as per Korea guide lines

Developed new latch boardWith PBT material as per global guide line.PBT is hard and brittle compared to POM so no chance of soft lock

POM Latch Board

Analysis

Harness TPA Addition

Reason :

Part :

- Harness connector in not TPA type

- Harness same blue color wire on two terminals

may cause connection error

- PCB Main (Power) Connector wire loose/open.

• No Display

• Intermittent Display

PCB Dead/Not working :

NG

Loose/Broken

Process :- Harness lot , sample basis checking in SQA

(visual inspection)

Action Plan:

Part :

- Add TPA in harness all models

-Make different wire colors in

harness to avoid connection

error

(With TPA)

TPA: Terminal Position Assurance

Process :

- Harness lot - To check 100% loose

connection at SQA

Issue Cause/Analysis Schedule

PDR Improvement Action Plan Suction Fan Extra Noise

Suction Fan Extra Noise

2013(R) 2014(Tgt)

20%

0.03%0.02%


Suction Fan0.02% 0.015%Suction Guide 0.01% 0.008%

Special Check point

• 100% Fan Alignment.

• Jig to be use at Fan Fixing and Motor Fixing Stage.

Defect Detail

MP

Test Std

Parts

1. Suction Fan Alignment Checking in input. 2. Suction Fan to be Fix by Jig to avoid mishandling.3. Suction Guide to be place on Jig before fixing the Motor to avoid bending.4. Sound Amplifier implemented in FQC to detect minor sounds.

1. Suction Fan Packing improved . Normal box to pizzon box.

2. Suction Guide Rib Strength increased to avoid bending.Fan Center Location Shift

1. 100%Suction Fan Flatness





DI Material

13’12 Mr. KaranDI R&D

14’01 C.P SinghDI Prod

14’03 Vinit QADI

Issue Cause / Analysis ScheduleSuction Guide Noise Issue

Cause and Inspection and Root cause

a)Noise from suction guide.

Inspection

■ Improvement Countermeasure

• Model / Tool : All• Country : India.• Issue occur : Field Claim

Phenomena : Noise from MWO

1.Noise from Suction Fan

Set Analysis

100% Check on prod line-Noise Chamber■ Analysis

a) Fan blade touching to suction guide.b) Filter assy vibration noise.c) Fan motor vibration.

Noise-chamber-ED

a) Fan blade touching to suction guide. Fan centre location shifted.

b) Filter assy vibration noise. Emboss added for filter assy support

c) Fan motor vibration. All emboss with same height.

2013 Quality Innovation Review SQA PRR

SQA PRR (PPM)

LRN

13160

1631613053

`12.Result

`13.Target

`13.Result

Good Point

Weak Point

Review 2012

Major issue status(YTD)

1. Roti Bar & Handle Quality Improved from vendor end2. Shelf High & Low Quality Improved From Vendor end3. 32L Latch Board Quality Improved 4. 32L Glass Tray Quality Improved5. 32L Model Controller Electrical Issues Decrease.6. Carton Box Moisture Issue decrease.7. Micro switch assembled at supplier end , lock broken

issue decrease.8. Heater Sheath removed ( Rejection was high )9. Cavity Rejection decrease . 10. Magnetron Quality Improved.

1. Heater Sheath HV/IR fail Increase2. Lamp rejection Increased3. 20 L grill Model Controller PCB rejection Increase4. Key Membrane defect increase.5. EPS Quality Issue increase.6. Glass tray crack line issue increase.7. Door Choke Cover Out issue increase.8. Controller Knob Free Issue increase.

19.34%

SQA Improvement Action Plan


Sheet Metal

Molding

Packing separator use each part protection for rubbing each other

Inspection Strenghtening before & after Assly

Mold Preventive maintenance schedule revised from 30 15days for flash issue.

DI Jan’14 Material

New Tool making for back cover.

8742

33%

`14 Tgt

13160

`13 (Result)

PDI Process Strengthening – Inspector Job RotationSQA Inspection Strengthening – Sample selection criteria revision

Time Check Process Strengthen For paint process

DI Sandeep

Handing improvement At Supplier End DI Mr. Kamaljeet Material

SQA

Packing Issue

Color Carton Box to be change in Khaki box to reduce moisture over issues.

DI Mat/SQA/R&D


Back Cover , - 18% - Black line & yellow mark

Steam Shelf- 11%

-Black Mark & Burr &Handle Welding Broken

Shelf High & low- 5%

- Welding Mark & Polishing NG

Door Assembly - 8%

Choke Cover Cut (During Removing

Flash) ,Flash in Choke cover Sealant out & paint

NG, Paint NG

,Scratch, Choke cover out

Carton box– 12%

Moisture Issue

Packing Table 32L- 3%

Less Height from one side

Mold Preventive maintenance schedule maintain at supplier end for EPS Mat/

SQA/R&D

DI

DI

DI

DI

Jan’14

Jan’14

Jan’14

Jan’14

Mr. Kamaljeet

Jan’14 MaterialMr.

Kamaljeet

Jan’14 SQAVinit

Jan’14 SQAVinit

Mr. Kamaljeet

Mr. Kamaljeet

Outgoing Quality Assurance2014 Target & Task of key action

Appearance

1) Paint Over DFT2) Glass Tray Strucking3) Door Paint Peel Off 4) MWO Dirty5) Wrong Screw Use6) Grease Missing 7) Screw Free8) Rotisserie Bar thickness Over9) Door Melt10) Door Glass Broken

Current Target Tool Deptt Start End19% 0 DI QA 14’01 14’0310% 0 DI QA 14’01 14’0310% 0 DI QA 14’01 14’035% 0 DI PROD 14’01 14’035% 0 DI PROD 14’01 14’035% 0 DI PROD 14’01 14’035% 0 DI PROD 14’01 14’035% 0 DI QA 14’01 14’035% 0 DI PROD 14’01 14’035% 0 DI QA 14’01 14’03


Design

Functional1) Lamp Fuse 2) Suction Fan Extra Noise3) Chamber Fan Extra Noise4) Back Cover Extra Noise

1) No Issue

OQA

20%↓

`13Result

`14.Target

2.5%

2.0%

28%

72%

0%

Current Target Tool Deptt Start End10% 0 DI Material 14’01 14’0310% 0 DI QA 14’01 14’035% 0 DI QA 14’01 14’035% 0 DI QA 14’01 14’03

2013 Quality Innovation Review OQA

OQA (PPM)

28082087

`13 Tgt `13 Result

3709

`12 Ach

E-Durables

43%↓

Good Point

Weak Point

Review 2013

1. Ring melt not found in ELT2. Extra screw in machine & screw loose not in OQA

ELT3. Power cord rej. Control.4. Screw Free Issue reduced.5. Part 3F Improved.6. Connector Open/Loose issue detection enhance.7. Part Failure ( MGT & T.T Motor reduce )8.

1. TT Motor not Work 2. Over DFT in Cavity & Outcase found in OQA & ELT3. Lamp fuse in ELT4. M/C Dead (capacitor & Diode Defective)5. MWO Extra Noise Issue Increase .

OQA Improvement Action Plan


1711

20%

`14 Tgt

2087

`13 (Result)

Reason: Lamp DefectedAction Plan: 1) Lamp Handling improved.2) Electrical Testing Started3) Lamp Packing Improved.


Reason: Fan Blade Alignment NG Action Plan: 1)100% Suction fan Alignment inspection2)Jig introduce for fan fixing.3)Noise Detection enhance

Reason: Back Cover Cocking Open Action Plan: 1)SQA JIR Revised .2)Noise Detection Enhance

Reason: Chamber Fan Bush touchingAction Plan: 1)Motor Bracket Hole ID Reduce.2)Jig Introduced for centric fitment of fan3)Fan Fixing Method Revised4)100% fan flatness inspection 5) Noise Detection enhance

1) Lamp Fuse

2) Suction Fan Extra Noise

3) Chamber Fan Extra Noise

4) Back Cover Extra Noise

14’01 QADI Vinit

14’01QA/ProdDI

14’01 QADIVinit/C.P Singh

14’01 QADI Vinit

Vinit/C.P Singh



1711

20%

`14 Tgt

2087

`13 (Result)


1) Paint Over DFT

Reason : Reworked cavity /OutcaseAction Plan: 1)Properly sanding cavity/ Outcase before repaint and marked rework cavity100% cavity inspected for over DFT.

2) Glass Tray Strucking

Reason: Cavity Embossing Height LessAction Plan: 1) SQA JIR Revised.2) Category wise Embossing Height Controlled .3) LQC Work instruction revised.

3) Door Paint Peel Off

Reason: Door Paint Not DryAction Plan: 1)Oven Temperature To be interlock with Conveyor.2) Sample Size Increase in SQA . 5 Nos 20 Nos

4) MWO Dirty

Reason: Dirty Hand GlovesAction Plan: 1)Time Check For Hand Gloves 2)Cleaning Cloth Change After Every 2 Hours.

14’01 QADI Vinit

14’01 QADI Tirath

14’01 QADI E-Vision

14’01 ProdDI C.P Singh



1711

20%

`14 Tgt

2087

`13 (Result)


5) Wrong Screw Use

Reason : Reworked cavity /OutcaseAction Plan: 1)Properly sanding cavity/ Outcase before repaint and marked rework cavity100% cavity inspected for over DFT.

14’01 QADI Vinit

6) Grease Missing

Reason : Skip by operator.Action Plan: 1)W.I Revised at Door Fixing Stage.2) Latching Operator will verify the same.

7) Screw FreeReason : Pneumatic High Torque.Action Plan: 1) FRL used at Outcase fixing stage

8) Rotisserie Bar Thickness Over

Reason : Thickness Error from supplier end.Action Plan: 1) 100% roti bar thickness inspection in input.2) In New Models Multi Roti Bar removed.

9) Door Melt

Reason : Cavity Front Plate Flatness Issue.Action Plan: 1) 100% Cavity Flatness Inspection in Input.2) Cavity JIR Revised.

10) Door Glass BrokenReason : Door Glass DefectedAction Plan: 1) Glass Reliability test Done At LG end .

14’01 QADI Vinit

14’01 QADI Vinit

14’01 QADI Vinit

14’01 QADI Vinit

14’01 QADI Vinit

2013 Quality Innovation Review OQA

FFR (%)

6.45

`13 Tgt `13 Result

7.43

`12 Ach

E-Durables-1.28%↓ Good Point

Weak Point

Review 2012

1. PCB Rejection / Functional Issue Reduce .2. Out case gap improvement.3. HVT Rejection Reduce .4. Carton Box Moisture Issue end.5. Accessory Missing issue Reduce.6. Appearance issue detection increase.7. Rotating Ring Broken Issue decrease.8. Lamp Failure decrease.

1. Harness Wire Issue Increase2. Door High Leakage issue increase.3. Door Melt Issue in 20 Ltr .4. Choke cover melt rej. Increase in 20 ltr. Model.5. 30 Ltr. Chamber fan touching .motor bracket issue.6. Convection & grill model oil fume not control.7. 30 Ltr. Convection heater IR fail rej. increase.8. Lamp fuse rej. Increase .9. Suction Fan Extra Noise Issue Increase .10. Magnetron rej. Increase.

7.53

FFR Improvement Action Plan


5.60 %

25%

`14 Tgt

7.53%

`13 (Result)


1) Magnetron Failure Issue

2) PCB Failure Increase

3) Diode Failure Increase

4) MWO Damage Issue

5) Non Part Issues

6) Latch switch Adjustment Issue .

7) Convection Fan Extra Noise

8) Suction Fan Extra Noise 9) Glass Tray Movement Free

10) Connector Open

D.I

D.I

D.I

D.I

D.I

D.I

D.I

D.I

D.I

D.I

13’09 – 13’12

13’09 – 13’12

13’09 – 13’12

13’09 – 13’12

13’09 – 13’12

13’09 – 13’12

13’09 – 13’12

13’09 – 13’12

13’07– 13’09

13’09– 13’12

R&D

EMS/R&D

R&D

EMS / R&D

EMS

EMS/R&D

EMS/R&D

EMS/R&D

R&D/Material

EMS/R&D

Mr. Dinesh

Mr. Dinesh

Mr. Dinesh

Mr. Karan

Vinit / C.P Singh

Mr. Karan

Mr. Karan

Mr. Karan

Mr. Karan

VinitMr. Dinesh

Part FFR - MGT

Issue.

Breakthrough Add Life Cycle test to check Part reliability.

Test Condition:-Sample: 08

Test Duration: 830Hrs.

System Change

Result

Anode Temp OKVoltage Cycle Test OKLife Cycle OKELT OK

Validation

Lvl 3 : Highest level in Divison, Lvl 2 : IL first, Lvl 1 : New standardized concept product

MGT (1.66%)

FFR Contribution 19%Cause :Running part has no design margin available i.e operating at 100% Efficiency.

Due to less margin part give reliability Issue and fail itself

Plan 1 2 3 4 5 6 7 8 9 10 11 12

Y'12R 1.65 1.69 1.66 1.68 1.69 1.75 1.89 2.15 2.71 2.60 2.17 1.76Y'13T 1.70 1.55 1.41 1.32 1.23 1.13 1.07 1.00 1.00 0.93 0.77 0.70Y'13R 1.59 1.46 1.40 1.33 1.25 1.20 1.32 1.41 1.66 1.78%Imp 4% 13% 16% 21% 26% 31% 30% 34% 39% 32%

Main Issue:-

1.Magnet Crack

2.Anode Cap burn

30%

Part FFR - PCB

Issue.

BreakthroughPower ON/OFF test for New PCB Design

Test Condition:-AC input up to 500V and ON/OFFUnit (Comparison Test)

System Change

Result

Spike Test OKVoltage Cycle OKON / OFF Test OK

Validation


Plan 1 2 3 4 5 6 7 8 9 10 11 12

Y'12R 0.69 0.67 0.61 0.57 0.53 0.49 0.51 0.59 0.76 0.83 0.77 0.68

Y'13T 0.68 0.65 0.61 0.6 0.58 0.55 0.54 0.53 0.54 0.55 0.52 0.49

Y'13R 0.63 0.58 0.53 0.51 0.47 0.47 0.56 0.63 0.77 0.85

%Imp 9% 14% 12% 12% 12% 3% -11% -7% -2% -2%

PCB (0.78%)

Contribution 9%

Main Issue:-

1.No Power

2.Cleaning

No Power Improvement

1. Fuse change to PTC

20L / 21L / 28L / 32L

Cleaning Issue:

Conformal Coating Applied

(20L / 21L / 28L / 32L)

2. Bridge Diode change to Discrete

(Vrrm Specs change 600 to 1000V)

20L / 21L / 28L / 32L

20%

Part FFR - HVD

Issue.

Breakthrough

ON / OFF Limit Test to check the part Sustainability.

Test Condition:-Main AC increase and Micro Mode ON/OFF (Comparison)

System Change

Result

ON / OFF Test OKELT OKLife Test OKSpike Test OK

Validation


HVD Assembly 0.38%

FFR Contr. 4%

Plan 1 2 3 4 5 6 7 8 9 10 11 12

Y'12R 0.22 0.22 0.22 0.21 0.19 0.18 0.17 0.18 0.20 0.21 0.19 0.20Y'13T 0.23 0.25 0.26 0.27 0.27 0.27 0.26 0.25 0.25 0.26 0.23 0.21Y'13R 0.23 0.26 0.29 0.30 0.32 0.33 0.34 0.34 0.38 0.42%Imp -7% -16% -33% -45% -66% -82% -98% -91% -88% ####

Issue

Protector Short

HV Protector change to HV fuse To reduce its failure at higher Voltages

HV Fuse

15%

Part FFR - Door

Issue Breakthrough- Drop height increase 60 100 cm.

- Ball impact test included to check glass strength.

System Change

Result

Transportation Test OKLQC Door Melt Improve

Validation


FFR 0.26%

Contri: 3%

Monthly Trend (New FFR)

Cause : Door handle hit on front side

because of less margin. Hinge dimension not maintained

as per spec.

Main Issue:-

1. Door Glass Broken

2. Choke Cover Melt

Improvement : New integrated packing design with increased depth and height . New hinge tool (progressive ) developed

Before After

Apply Date: New Packing: 32L Jan’13 28L Feb’13 21L Oct’13 New Hinge Tool : 28L ->May’13 21L ->Jun’13

10%

Non Part

Issue.

Breakthrough System Change

Result

Validation


Non Part 3.63%

FFR Contribution 46%

•TPA Added in Harness

•All Dealer Call will go in Non FFR code

•100% Checking on line for loose connection.

•QRG added for installation issues.

•Suction Guide centering done

•Vinyl Bag change to Lami Bag to improve scratch issues

•Conformal coating applied on PCB to •Improve PCB related issue.

•Std. demo guide for service engineers to improve demo quality.

•HV Protector change to HV Fuse

•Lamp packing improved

• Electrical gun used for latch board tightening instead of manual

• Continuous Feedback to production line for non part issues.

• Add Inspection on critical stages

6M FRR showing improvement trend

10%

Main Issue:-

1. Part Adj– Harness/Fuse/Door switch

2. Cleaning– Cavity/Glass Tray

3. Electrical – House wiring/Socket

4. Explanation– Functional/Recipe related


Non Part - Door switch Adjust (soft lock)

Logic Tree Analysis Improvement Door switch Adjust (soft lock)Model : 32 Ltrconvection

Sof

t loc

k is

sue

POM is soft and self lubricating material

it leads to improper switch operation in field

Conclusion

While repeated forcefully Opening and closing the door , switch fixing area becomes weak

Due to repeated pressing the switch fixing area further reduces in strength

Currently using latch board with POM material

NEED to develop latch board with hard material such as PBT as per Korea guide lines

Developed new latch boardWith PBT material as per global guide line.PBT is hard and brittle compared to POM so no chance of soft lock

StatusFPA completed4M completed

POM Latch Board

Costing MP

11th May 14th May

Schedule:

Analysis

Trial


Non Part -Guide Chamber Noise Issue

Logic Tree Improvement Bush touch noise in convection chamber

Noi

se Motor shaft misalignment

Conclusion

Motor bracket warpage

Analysis

Fan Blade warpage

Bush touching in guide chamber

Motor bracket draw height NG

1.Motor bracket hole more than outer chamber

2.Hole size mismatch give rise to play in the

assembly .

Tool modification done for motor bracket hole 5 mm -- > 4.2

4.2 mm

Before After

5 mm

Tool modified : 9th Apr’13

Stock Available : 1000

Implementation: 15th Apr’13

Guide Chamber Assembly

5 mm

M 4

Bush

Motor Shaft

Chamber Wall

Bush Touch with inner chamber

Outer chamber wall

12+0.2 mm

4.5 mm

Issue Cause / Analysis ScheduleNon Part – Suction Guide Noise Issue

Cause and Inspection and Root cause

a)Noise from suction guide.

Inspection

■ Improvement Countermeasure

• Model / Tool : All• Country : India.• Issue occur : Field Claim

Phenomena : Noise from MWO

1.Noise from Suction Fan

Set Analysis

100% Check on prod line-Noise Chamber■ Analysis

a) Fan blade touching to suction guide.b) Filter assy vibration noise.c) Fan motor vibration.

Noise-chamber-EDNoise-chamber-amber

a) Fan blade touching to suction guide. Fan centre location shifted.

b) Filter assy vibration noise. Emboss added for filter assy support

c) Fan motor vibration. All emboss with same height.

Defect Phenomenon

Non Part : Glass Tray Fitment Issue

Cause/Analysis Issue Cause/Analysis Schedule

ScheduleGlass tray fitment issue in 20L

models1. Turntable assy not supported at the centre unlike

other categories.2. Depth of glass tray rib is less for roller rotation.

Before AfterSamplereceive

10/6

ProductTest

17/6

PO

18/6 25/8

Apply

Rib

PO

22/7 25/7

ETD

Revised Schedule

July Opening - 10000In transit - 1344July ETD - 3000 – 7th Jul - 17160– 23rd Jul Aug ETD - 8064 – 11th Aug 39586

Apply

25/8

15/911/8

PCB- Harness TPA Addition

Reason :

Part :

- Harness connector in not TPA type

- Harness same blue color wire on two terminals

may cause connection error

- PCB Main (Power) Connector wire loose/open.

• DOA/

• No Display

• Intermittent Display

• Wiring Adj.

PCB Dead/Not working :

NG

Loose/Broken

Process :- Harness lot , sample basis checking in IQC

(visual inspection)

Action Plan:

Part :

- Add TPA in harness all models

-Make different wire colors in

harness to avoid connection

error

(With TPA)

TPA: Terminal Position Assurance

Process :

- Harness lot - To check 100% loose

connection at IQC

Issue Cause/Analysis Schedule

Return

Issue.

Breakthrough System Change

Result

Validation


Return FFR 0.24%

Contribution 2.7%

Monthly Trend (New FFR)

1. Packing Improvement for dent

2. Lami bag added for scratch

3. TPA addition in harness

4. Policy change for return DR GR

Drop height increase

60 100 cm.

6M FFR also showing improvementMain Issue:-

1. DOA– PCB/MGT

2. Dent/Scratch

3. Customer Dissatisfaction

10%

Issue Cause / Analysis Improvement/Schedule

Improvement Idea : 1) New integrated packing design with 50 mm

Height increased 2) Increased drop test height 0.6m 1m

Implementation: Issue : Outcase Dent Analysis :

Outcase Case Dent during transit.

Before After

Simulation : - Transportation test done with integrated

packing and increased ht 0.61m - No dent on outcase observed. Packing Upper :-

Height increase by 50mm

Return: Packing Improvement- Out Case Dent

Model wise apply date:

quality innovation plan

Engineering