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SKF Six Sigma

1

© SKF Group

SKF in India

Slide 1

© SKF Group

© SKF Group

SKF vision and mission

A world of reliable rotation

The undisputed leader

in the bearing business

Slide 2

SKF Six Sigma

2

© SKF Group

© SKF Group

© SKF Group

High Ethics

Openness

Empowerment

Team Work

VALUES

DRIVERS Grow with Profit

Quality

Innovation

Simplicity & Speed

Sustainability

SKF Commitment

Slide 3

© SKF Group

© SKF Group

SKF – a truly global company

● Established 1907

● Sales 2015 8.92 billion USD

● Employees 48,593

● Production sites around 165 in 29 countries

● SKF presence in over 130 countries

● Distributors/dealers 15,000 locations

● Global certificates ISO 14001

OHSAS 18001 certification

ISO 50001

Slide 4

SKF Six Sigma

3

© SKF Group

© SKF Group

© SKF Group

SKF Technology areas

Bearings

and units

Seals Services Lubrication

systems

Mechatronics

Slide 5

© SKF Group

© SKF Group

SKF in India : Manufacturing facilities

DGBB

Pune TRB /HUB

DGBB

Seals

Bangalore

Mysore

Large size

bearings

Ahmedabad

DGBB

Pune Factory

TRB,DGBB, MSBU, HUB, HBU

Spindle Service Centre

Solution Factory

Bangalore Factory

• Small DGBB

• VAS Manufacturing

• Application

Development Centre

• GTCI

Haridwar Factory

Small DGBB

Ahmedabad Factory

Large Size Bearings

Cylindrical roller Bearings

Spherical Roller Bearings

Mysore

Factory

Seals

Haridwar

Lubrication

Business Unit

Slide 6

SKF Six Sigma

4

© SKF Group

© SKF Group

© SKF Group

Slide 7

Pune Factory Products

© SKF Group

© SKF Group

Slide 8

Our Automotive Customers

Domestic Global

SKF Six Sigma

5

© SKF Group

© SKF Group

2017-03-08

Slide 9

Our Industrial customers

© SKF Group

SKF Production System

The lasting organisational benefits of a culturally driven, behaviour based approach,

augmented with the data driven discipline Slide 10

1.1.1 Q2

http://www.suzlon.com/index.aspx

http://www.vestas.com/en/

http://www.cglonline.com/

http://www.escortsgroup.com/index.htm

http://www.alstom.com/

http://www.metso.com/

SKF Six Sigma

6

© SKF Group

© SKF Group

SKF Production System

Slide 11

1.1.1 Q2

© SKF Group

Six Sigma in SKF India Ltd.

Slide 12

Resource spread across units in India

Six Sigma

Resources

(Belts inducted

from 2008 to 2015)

DMAIC

(2015)DMAIC DMAIC DMAIC DFSS

Business Unit / BeltsWhite Belts Green Belts Black Belts MBB Green Belts

DGBB Bangalore Yes Yes Yes

TW Bangalore Sales Yes Yes

DGBB Haridwar Yes Yes Yes

DGBB Pune Yes Yes

LSB Ahmedabad Yes Yes

LBU Bangalore Yes Yes

GTCI Bangalore Yes Yes Yes

TRB Pune Yes Yes Yes

Seals Mysore Yes Yes Yes

SLS Pune Yes Yes

Purchasing Yes Yes

IM Sales Yes Yes

AM Salea Yes Yes

Co Six Sigma Yes Yes Yes

CO HR Yes Yes

All Belts are Part Time ( Functional role)

233

284

324 354

297

248 280

200

0

50

100

150

200

250

300

350

400

2008 2009 2010 2011 2012 2013 2014 2015

Saving in MINR

1.6 1.5 1.6 1.8

1.5 1.5

3.2

2.5

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

2008 2009 2010 2011 2012 2013 2014 2015

ROI per project in MINR

SKF Six Sigma

7

© SKF Group

© SKF Group

Six Sigma Roles & Responsibilitys

Slide 13

1.1.1 Q1

© SKF Group

Morale

Six Sigma contribution to Enhance overall Business Performance and Culture

Six Sigma Projects identification

Project Hopper

Process

Slide 14

1.1.1 Q2

SKF Six Sigma

8

© SKF Group

Clamping unit cost reduction by 30% per annum

from 1 % wrt VASC to 0.7 % wrt VASC in year 2015

Team :

Hemant Dewoolkar (Manufacturing)

Shrinivas Panse (Resetting)

Uday Rokade (Presetting)

Santosh Mhaske (Stores)

Ambadas Pawar (Maintenance)

Amit Zanzurne (Purchase)

Shekhar Bhosale (Resetting)

Sponsor : Nitin Ghatpande Process Owner : Gopal Sakala

Black Belt : Gopal Sakala MBB : Rahul Pawar

Slide 15

© SKF Group

Why this project ?

Slide 16

Ch. manager

Ch. manager

Mfg. head

Let’s

initiate the

project

SKF Six Sigma

9

© SKF Group

© SKF Group

QCD – Project identification

Cost impact is 1 % of Total VASC

Total Shop Supplies

200 MINR

Other Cost ( >8

categories)

157 MINR

Tooling Cost

43 MINR

Clamping unit

16.8 MINR

Other (>1000 items)

25.6 MINR

Clamping unit

Spare Cost

12.2 MIR

Clamping unit

Repair Cost

4.6 MINR

Lost Hrs

Slide 17

3.2.4 Q1 &

Q2

1.2.1 Q1

2.1.1 Q2

© SKF Group

Gap Analysis / Deviation

Project Presentation Slide 18

Highest cost deviation

w.r.t. Business plan

1.2.2 Q1,

Q2 & Q3

1.2.1 Q1,

Q2 & Q3

SKF Six Sigma

10

© SKF Group

© SKF Group

Tooling cost breakup

Slide 19

Clamping unit

spares cost

contribute to 24%

in overall tooling

cost

Clamping unit 16.8 MINR/ Annum

1.2.2 Q1

© SKF Group

What is Clamping unit ?

Project Presentation

Clamping unit

Function Hold the inner ring while grinding which is most critical operation in

bearing manufacturing

Slide 20

Used on all internal grinding machines

All these m/cs are bottleneck

Operation is last finish operation

Any deviation will lead to rejection or customer

complaint

SKF Six Sigma

11

© SKF Group

© SKF Group

Clamping unit


• Used on >30 bottleneck machines, if

this stops, entire line stops

• 19 varieties

• Total 155 clamping units are in use

• Everything is interchangeable

• Used for >3000 product variants

….

© SKF Group

Clamping unit details - Spares


Bangle

bearing

Step seal

set-1

Step seal

set-2

Step seal

set-3

Lammelring

Piston

Collar

(Inner ring

Cap (Cover)

SKF Six Sigma

12

© SKF Group

© SKF Group

Baseline : Clamping unit cost % wrt value added cost

Avg. Clamping unit cost % wrt Value

added cost = 0.98 %

Standard deviation = 0.23

Practical implication : Loss of profitability

is @ 1% due to clamping unit cost

Slide 23

© SKF Group

Spindle Services

Factory

Resetting Grinding Store

Cha

nn

el

M/c

General Store

Repair Unit for Repair

Repaired Unit

Failed unit submit to GRD store

Good Unit for use to channel

Failed

Unit

Spares Received

Spares Request

Cost

Quality Down

Time

Slide 24

SKF Six Sigma

13

© SKF Group

© SKF Group

Project Charter – Pg. 1/3


Metrics BaselineOutcome

(Goal)

Clamping units for internal

grinders' spares cost in shop

supplies cost

11.96 /

Annum8.37 / Annum

Overall cost due to all internal

grinders' clamping unit for

TRB & HBU

16.88 /

Annum

11.81 /

Annum

Overall cost per clamping unitRs. 9152 /

unit

Rs. 6400 /

unit

Defect

DefinitionCost due to clamping unit reduction less than 30 %

Business

Benefits

Overall shop supplies and repair and maintenance cost

reduction for TRB and HBU, Overall cost saving of more

than 5 MINR / annum

Outcome

condition

KPO

RequirementCost due to clamping unit reduction by 30 %

Work Package Definition - what is the problem and how is it quantified

Key Process

Output (KPO)

Reduction of cost due to internal grinder (IR Bore and OR

Track/Groove) clamping units

Customer TRB, HBU channels and Grinding stores

2.1.1 Q1 1.2.3 Q1,

Q2 & Q3

© SKF Group



Start

point

Process

End

point

Dependencies /

Interfaces

Channel team, Grinding Store, General Store, Spindle

Serviecs, Maintenance, Engineering, Presetting team

Product /

Service Family

Selected

All clamping units used for internal grinders on all TRB

and HBU channels (Bangle bearing and conventional

clamping units)

Suppliers Grinding store, General store, Channel

Exclusions

(Supplier

Inputs)

IR track, IR flange, IR & OR Honing clamping units

Inc

lus

ion

s

Clamping unit for repair from store

Clamping unit use on channel and repair

Ready for use clamping unit to store

Inclusions / Exclusions - scope for boundaries

1.2.3 Q1 &

Q3

SKF Six Sigma

14

© SKF Group

© SKF Group



AD-GS-20160302-

52060

Automotive Market

Pune

Gopal Sakala

Nitin Ghatpande

Nitin Ghatpande

Rahul Pawar

7/30/2015

Approved By Role Date

N.G.GhatpandeGM

Mfg.2-Aug-15

WP Start date

WP Target

completion

date

4/20/2016

Consider team

members/compete

ncies after scope

has been

determined.

Local

Process

Owner

Six Sigma

ManagerController Amol Dagdiya

Work Package

Title

Cost due to Clamping unit (for internal grinders) reduction

from 16.88 MINR per annum to 11.81 MINR per annum,

30% reduction

WP Reference

NumberLast Update 3/1/2016

Organization

ABUWP

Authorization

General Information

Business Area Business Unit TRB

Site / LocationEquipment

(if applicable) -

Work Package

ManagerWP Category Black Belt

SponsorWP Team

Members

Project Objective

Statement

2.4.1 Q1 1.2.3 Q1 &

Q3

© SKF Group

SIPOC


Process name: Clamping unit repair

Process owner: TRB, HBU Manufacturing

S P C Suppliers Process Customers

Providers of the

required resources

Resources required

by the process

Numerical requirements

on inputs

Top level description

of the activity

Deliverables from

the process

Numerical requirements

on outputs

Stakeholders who place the

requirements on outputs

Requirements Requirements

Channel

Operator

Machine

Allen key

Ring

Used clamping unit

returned to store

for repair

Grinding Store

SOP

Operator Clamping unit in Solution factory

Trolley spindle services

Grinding store Repair tag

SOP

Repaired clamping

Solution factory Clamping unit spares unit Solution factory

Operator Reair cost to

Tools respective channel

Spare cost to

respective channel

Smooth working Solution factory

Solution factory Checking test rig unit

Solution factory Repaired unit Grinding store Grinding store

stock improved

Grinding Store Repaired clamping unit Unit mounted on Channel / Presettig

machine

Inputs Outputs

I O

Used / Failed clamping unit

return to presetting or store

Repair of clamping unit

Hand over

clamping unit for

repair to Solution

factory

Reapired unit

inspection

Issue unit to channel /

Presetting as & when required

Retun repaired unit

to grinding store

Team members will be

required from

• Manufacturing

channel

• Grinding Store

• Presetting

• Maintenance

• Purchase

Bird’s eye view for entire process & stakeholder identification

1.3.1 Q1 &

Q2

SKF Six Sigma

15

© SKF Group

© SKF Group

Stakeholder register -


Project Name :

Prepared by :

Date :

Specific information

needsProject Interests Impact on Project Role

Types & frequency of

communication

Specific areas of

Ineterest &

Participation

Positive,

Negative,

Influencer,

Supporter,

Roadblock

Decision Maker,

Collaborator,

Participant,

Consultanat,

Information,

Recipient

Channel operator Oral - Daily Positive Decision Maker

Channel Supervisor Oral/Mail - Daily Positive Collaborator

Channel Manger

Oral/Mail, Monthly

report - Daily,

Monthly

PositiveDecision Maker &

Recipient

Stores inchargeConsumption form -

DailyPositive Decision Maker

Stores operatorConsumption form -

DailyInfluencer Collaborator

Presetting operator Planning form - Daily Positive Decision Maker

Presetting incharge Mail/Oral - Daily Positive Decision Maker

Solution factory (supplier) Repair form - Daily Positive Collaborator

Transporter Invoice - Daily Supporter Information

Central Store operatorConsumption form -

DailySupporter Information

Central Store managerConsumption form -

DailySupporter Information

BuyerPurchase requisition

/ Mail - FrequentlyPositive Decision Maker

Maintenance operator Repair form - Daily Supporter Information

Maintenance Manager Repair form - Daily Supporter Information

ABU - Manufacturing headConsumption report -

Monthly / weeklyPositive

Decision Maker &

Recipient

Project stakeholder name

Stakeholder Register

Clamping unit cost reduction by 30% per annum, from 16.8 MINR/ Annum to 11.8 MINR /

Annum

Gopal Sakala

Sep-15

Selected as

Team

Members

1.3.4 Q1 &

Q3

1.3.1 Q1 &

Q2

© SKF Group

Team Members -


Project Sponsor Nitin Ghatpande

Project Leader Gopal Sakala

Review Board Nitin Ghatpande

Rahul Pawar Amol Dagdiya

MBB Rahul Pawar

Hemant Dewoolkar

Team :

Reduction of Clamping unit cost Objective

Clamping unit cost reduction by 30% per

annum from 1 % w.r.t. VASC to 0.7 % w.r.t. VASC

Shrinivas Panse

Amit Zanzurne

Uday Rokade

Santosh Mhaske

Ambadas Pawar

Shekhar Bhosale

1.3.1 Q2

SKF Six Sigma

16

© SKF Group

© SKF Group

Project Planning

Activity description Phase Tool used Status Start date End dates

Wk-

31

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P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

P

A

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P

A

Road map for black belt project "Clamping unit cost reduction from 16.88 MINR to 11.81 MINR, 30% reduction"

20-Sep 10-Nov

16-Nov 02-Dec

10-Dec 05-Jan

08-Sep 15-Sep

21-Sep 22-Sep

20-Aug 20-Sep

26-Aug 28-Aug

26-Aug 04-Sep

04-Sep 05-Sep

17-Aug 23-Aug

24-Aug 25-Aug

24-Aug 26-Aug

26-Aug

14-Aug 22-Aug

10-Aug 25-Aug

Control ControlControl

plan

06-Aug 06-Aug

06-Aug 06-Aug

06-Aug 14-Aug

24-Aug

Implementation Improve

Deviation identification

methodControl

Daily

manageme

Workshop for action

identificationImprove

Low hanging fruit - actions Improve

Causes prioratization AnalysisC & E matrix /

Ease impact

grid

Validation Analysis

Key impacted area selection AnalysisEase and

impact grid

Workshop for Root Cause

AnalysisAnalysis

Fish bone,

why-why

Fault tree analysis Analysis FTA

Feasibility study AnalysisEase and

impact grid

Data collection (Raw data) MeasureData

collection

Stratification of cost AnalysisPareto,

Multi level

Process Flow Define SIPOC

Refer old projects Define

T-map Measure T-map

Saving verification with

controllerDefine

MSA of baseline Define MSA

Project launch in database Define 01-Aug 01-Aug

Base line data collection DefineData

collection 03-Aug 06-Aug

01-Aug01-AugDefineProject kick off

Project charter Define PC 03-Aug 06-Aug

Metric selection Define 01-Aug 01-Aug

Slide 31

1.3.4 Q2

© SKF Group

Planned reviews and meetings

(Fixed)


Planned closing

meeting

3.3.1 Q1,

Q2 & Q4

2.4.1 Q2 &

Q4

1.3.4 Q3

5.2.1 Q1

SKF Six Sigma

17

© SKF Group

© SKF Group

MSA of Baseline – Big Y

Whs Item Description Posted MONTH Reason Txn Quantity Transaction amount

800 6800492 Ball Bearing Fpxb-608 Skf Make 30/09/2015 2015 SEP 1306 = IS TRB Channel 6 1 16,371


800 6800532 Ball Bearing-fpxa-300 28/09/2015 2015 SEP 1307 = IS TRB Channel 7 1 7,001




800 6190222 Step Seal-RSZH040335T05 25/09/2015 2015 SEP 1501 = IS HBU 1 1 16,514

800 6190214 Step Seal Turcon-RSZHO40334T05 25/09/2015 2015 SEP 1501 = IS HBU 1 2 24,221

800 6800202 Ball Bearing Fpxb-500 Skf Make 25/09/2015 2015 SEP 1501 = IS HBU 1 2 29,941



800 6800492 Ball Bearing Fpxb-608 Skf Make 25/09/2015 2015 SEP 1504 = HUB1 T 1 16,371








800 6190214 Step Seal Turcon-RSZHO40334T05 19/09/2015 2015 SEP 1501 = IS HBU 1 1 12,111

800 6190222 Step Seal-RSZH040335T05 19/09/2015 2015 SEP 1302 = IS TRB Channel 2 1 16,514

800 6190214 Step Seal Turcon-RSZHO40334T05 19/09/2015 2015 SEP 1302 = IS TRB Channel 2 1 12,111



Slide 33

Consumptions & cost data taken from

system & validated with controller

© SKF Group

Team &

Stakeholders


Role Area of

working

Time

required

Responsibilities / Roles Competencies

Required

Nitin Ghatpande

(Project Sponsor)

Head of a function 10% -Appoint project leader

-Provide resources and budget

-Frequent review

-Permission of closure

Six Sigma black belt

Gopal Sakala

(Project leader)

In charge of a function 50% -Lead project activities

-Team selection

-Communication

-Complete project as per decided time frame

Six Sigma black belt

( Gap - Need Training)

Shrinivas Panse

(Team Member)

Channel 10% -Complete assigned activities / Sub projects

-Solution development

-Monitor changes/results

Six Sigma White belt

Uday Rokade

(Team Member)

Presetting 10% -Complete assigned activities / Sub projects



Six Sigma White belt

Santosh Mhaske

(Team Member)

Grinding Store 10% Complete assigned activities / Sub projects



Six Sigma Green Belt

( Gap - Need Training)

Shekhar Bhosale

(Team Member)

Resetting + Engineering 15% Complete assigned activities / Sub projects




Ambadas Pawar

(Team Member)

Maintenance 10% Complete assigned activities / Sub projects




Amol Dagdiya

(Controller)

Controlling 5% -Provide financial reports

-Assist in interpretation

-Financial savings calculation


Rahul Pawar

(Facilitator)

Business Excellence /

Six Sigma

10% -Train project leader and team members

-Guide during project

-MIS Sharing

Master Black belt

1.3.4 Q1

2.2.1 Q3

Training given wherever

gap observed

1.3.3 Q1,

Q2

1.3.2 Q1,

Q2 & Q3

2.3.1 Q3

3.1.1 Q3 3.2.1 Q3

SKF Six Sigma

18

© SKF Group

© SKF Group

Kick off meeting Project

Declaration by Sponsor


• Sponsor and project leader conducted

meeting

• Background for selection of project

explained to team

• Sponsor explained objective and

expectations from project

• Team members declared

• Common consensus made

1.3.3 Q2

© SKF Group Slide 36

SKF Six Sigma

19

© SKF Group

© SKF Group

Identification of High cost Spars

Identification of High consumption spars

Challenging Cost of spars

Challenging Life of spars

Challenging Process

Slide 37

© SKF Group

Tooling cost breakup

Slide 38

Clamping unit

spares cost

contribute to 24%

in overall tooling

cost

Clamping unit 16.8 MINR/ Annum

2.2.2 Q1

SKF Six Sigma

20

© SKF Group

© SKF Group

Prioritisation – Clamping unit spares cost

(Pareto)

Bangle Bering

78.9 %

Step Seal

19.4 %

Total

98.2 %

Slide 39

2.2.2 Q1

© SKF Group

Clamping unit Cost

16.8 MINR

Spar Cost

12.2 MINR

Repairing Cost

4.6 MINR

Bangle Bearing

9.6 MINR

Step Seal

2.4 MINR

Other

0.2 MINR

Outsourced

Process

Approach

Challenging Life

Challenging Cost

Approach

Challenging Life

Challenging Cost

Approach

Challenging Life

Challenging Cost

Challenge quality

of repair

DMAIC

TRIZ DMAIC Lean

30%

Reduction 30%

Reduction

Slide 40

2.2.1 Q1 &

Q2

SKF Six Sigma

21

© SKF Group

© SKF Group

Clamping unit Cost

16.8 MINR

Spar Cost

12.2 MINR

Repairing Cost

4.6 MINR

Bangle Bearing

9.6 MINR

Approach

Challenging Life

Challenging Cost

DMAIC

TRIZ

Slide 41

© SKF Group

2015-01-30 Project Presentation

Bangle bearing

Slide 42

Bangle

bearing

Bangle

bearing

Function is

to rotate

component

during

grinding

operation

SKF Six Sigma

22

© SKF Group

© SKF Group

Converting noise factor into controllable factors


Clamping unit

use on m/c

Grinding Store Repair at

supplier end

Spare storage at

general store

Existing Process

X,= Machine

parameters

X₂= Lubrication

systems

X₃ = Storage

conditions

X₄ = Shelf life

X₅ = Repair

process

X₆ = Spare

consumption

X₇ = Repair

skill

X₈ = Effectiveness

of repair

X₉ = Authenticity

X₁₀ = Spares

Issue data

Noise Factors

Noise Factors

© SKF Group

Converting noise factor into controllable factors


Clamping unit

use on m/c

Grinding Store Repair at

supplier end

Spare storage at

general store

Clamping unit

use on m/c

Grinding Store Repair in

house

Spare storage at

general store

Existing Process

Improved Process

Challenges for in house repair –

Convincing management

Knowledge of repair

Setup of repair

Manpower

SKF Six Sigma

23

© SKF Group

© SKF Group Project Presentation

Fish bone diagram for causes identification

for Bangle bearing failure

Bangle

bearing

failure

Lubrication not

working on m/c

Mistake during

setting

Damage of

bearing during

removal

MAN MACINE METHOD

MANAGEMENT MOTHER

NATURE MATERIAL

Clamp de-clamp

air difference

Direct coolant jet

on clamping unit

Open hole given

on cover plate for

coolant exit

Cover plate bend

issue

Cover plate

center open hole

wr.t. clamping

plate

Lubrication for

declamp supply

Snap ring

thickness

Snap ring

material

Hydrofit washer

thickness

Damage of

bearing during

mounting

Lammelring not

fitted

Inspection of

basic condition

Clamping unit

effect checking

by operator

Clamping plate to

cuck face matching

procedure

Sealant coming

out during

running

No sufficient time

given for drying

sealant filled

Slide 45

2.2.1 Q1 &

Q2

© SKF Group

C&E Matrix & FMEA for Bangle bearing

Six Sigma Cause & Effect Matrix - Bangle bearing

1 2 3

Rating of Importance to

Customer10 7 10

Key Process Outputs

Bang

le b

earin

g life

Cos

t of s

ervi

ce

Qua

lity o

f

clam

ping

uni

t

Process Step Process Input Total

1 Damage of bearing during mounting / removal 9 9 9 243

2Inspection of basic condition on machine (e.g.

Lubrication, pressure, etc)9 9 9 243

3 Lammelring not f itted 9 9 9 243

4 Lubrication for declamp supply 9 9 9 243

5 Lubrication not w orking on m/c 9 9 9 243

6 Clamping unit effect checking by operator 9 9 9 243

7 Sealant coming out during running 9 9 9 243

8 No suff icient time given for drying sealant f illed 9 9 9 243

9 Open hole given on cover plate for coolant exit 9 3 9 201

10 Clamp de-clamp air difference 3 9 9 183

11 Mistake during setting 3 3 3 81

12 Direct coolant jet on clamping unit 3 3 3 81

13Clamping plate to chuck face matching

procedure3 3 3 81

14 Cover plate bend issue 3 3 3 81

15Cover plate center open hole w r.t. clamping

plate3 3 3 81

16 Snap ring thickness 3 3 3 81

17 Snap ring material 3 3 3 81

18 Hydrofit w asher thickness 3 3 3 81

1080 756 1140Total

C & E Matrix FMEA

Probable causes found after FMEA

• Bangle bearing failure frequently due to wrong fitment

• Bangle bearing found jam due to coolant & dust entry

• Lammelring fitment not done due to difficulty in fitment

• Wrong judgment of operator for functionality of clamping unit

• Coolant found inside cover plate which enters into bearing

Slide 46

3.1.2 Q1 2.3.2 Q1,

Q2, Q3

2.3.1 Q1 &

Q2

SKF Six Sigma

24

© SKF Group


Solution generation – Brain Storming

session

Sr. no. Causes Probable solutions to eliminate cause

1 Bangle bearing found jam due to coolant & dust entry 1. Modify coolant arrangements on machines

2. Modify design of unit to avoid coolant entry

3. Provide air sealing to eliminate entry of coolant

4. To make coolant arrangement on chuck itself

1 Bangle bearing failure frequently due to wrong fitment 1. Provide training to supplier for bearing fitment

2. Start clamping unit repair facility at our end

3. Check technical feasibility of mofying resting of bearing

for easy entry

4. Develop and provide fixture for bearing fitment to

supplier

3 Lammelring fitment not done due to difficulty in fitment 1. Modify design of lamellring

2. Modify arrangement of slot on claming unit

3. Train operator for proper fitment

4 Wrong judgment of operator for functionality of clamping unit 1. Provide easy arragement on machine

2. Train operator for development of judgemental skill

3. Make test rig in presetting for clamping unit checking

5 Coolant found inside cover plate which enters into bearing 1. Provide additional hole on cover plate

Team Meeting subject : Development of solutions / ideas for improing bangle bearing life

Present Members : GDS, ULR, SP, SB, AP

Total 15 ideas for

eliminating 5 causes

Slide 47

3.1.2 Q1,

Q2 & Q3

3.1.1 Q1 2.3.2 Q3


Finalization of solution –

Pugh Matrix

Ease of

impleme

ntation

Design

fesibility

Overall

cost

Lead

time

Easy for

operator

Sustenan

ce

1. Modify coolant arrangements on machines 2 2 1 3 1 2 11

2. Modify design of unit to avoid coolant entry 5 5 5 4 5 5 29

3. Provide air sealing to eliminate entry of coolant 1 1 1 1 1 1 6

4. To make coolant arrangement on chuck itself 1 2 1 1 4 3 12

1. Provide training to supplier for bearing fitment 5 5 5 5 1 1 22

2. Start clamping unit repair facility at our end 1 5 5 5 5 4 25

3. Check technical feasibility of mofying resting of bearing

for easy entry1 1 4 3 5 5 19

4. Develop and provide fixture for bearing fitment to

supplier2 4 3 4 4 2 19

1. Modify design of lamellring 5 4 3 3 4 4 23

2. Modify arrangement of slot on claming unit 1 1 5 3 4 5 19

3. Train operator for proper fitment 3 5 5 5 3 2 23

1. Provide easy arragement on machine 2 1 1 1 1 1 7

2. Train operator for development of judgemental skill 2 5 5 5 2 2 21

3. Make test rig in presetting for clamping unit checking 5 5 2 2 5 5 24

5Coolant found inside cover plate which

enters into bearing1. Provide additional hole on cover plate

Total

Score

Criterias (1-Low feasibility, 5-High feasibility)

4Wrong judgment of operator for

functionality of clamping unit

3Lammelring fitment not done due to

difficulty in fitment

2Bangle bearing failure frequently due to

wrong fitment

1Bangle bearing found jam due to coolant &

dust entry

Team Meeting subject : Finalization of solutions / ideas for improing bangle bearing life

Present Members : GDS, ULR, SP, SB, AP, AZ, SM

Sr. no. Causes Probable solutions to eliminate cause

1Bangle bearing found jam due to coolant &

dust entry2. Modify design of unit to avoid coolant entry

2Bangle bearing failure frequently due to

wrong fitment2. Start clamping unit repair facility at our end

3Lammelring fitment not done due to

difficulty in fitment1. Modify design of lamellring

4Wrong judgment of operator for

functionality of clamping unit3. Make test rig in presetting for clamping unit checking

5Coolant found inside cover plate which

enters into bearing1. Provide additional hole on cover plate

Sr. no. Causes Final solutions to eliminate cause

Slide 48

3.2.1 Q1,

Q2

3.1.1

Q1, Q2

2.4.1 Q2

2.4.1 Q3

2.3.3

Q1, Q2

3.2.2 Q1,

Q2

SKF Six Sigma

25

© SKF Group


Probable difficulties in implementation of

solutions

Slide 49

Sr. no. Final solutions to eliminate cause What can go wrong in implementation Action PIC Date of completion

1 Modify design of unit to avoid coolant entry

Competancy for designing Appoint one engineer from engineering team Hemant 28th Sept

Supplier lead time for manufacturing can be high Keep supplier in loop from desing stage & keep forging ready

Amit 29th Sept

2 Start clamping unit repair facility at our end

Availability of skilled operator To make diploma trainee available in channel T5 & spare Mr. Panse

Hemant 23rd Sept

Compatibility of reapir of clamping unit to opeator Give training on details of drawing and at supplier end to Mr. Panse

Gopal 28th Sept

Availability of place and equipment To make list of required equipment and make them available

Gopal 25th Sept

3 Modify design of lamellring

Competancy for designing Appoint one engineer from engineering team Hemant 28th Sept

Supplier lead time for manufacturing can be high Keep supplier in loop from desing stage & keep forging ready

Amit 29th Sept

4 Make test rig in presetting for clamping unit checking

Competancy for designing Appoint one engineer from engineering team Gopal 25th Sept

Budget may not be available Discuss with sponsor and make budgetory provision

Gopal 23rd Sept

Supplier lead time for manufacturing can be high Keep supplier in loop from design stage & keep forging ready

Amit 29th Sept

5 Provide additional hole on cover plate

Cover plate may become weak Discuss with engineering and finalize new drawing

Shekhar 1st Oct

Black Hats

4.1.3 Q1,

Q2

4.1.2 Q1,

Q2 & Q3

3.3.1 Q3

© SKF Group Project Presentation Slide 50

Sr. no. Causes Final solutions to eliminate cause PIC Target date of

completion Actual date of

completion Status

1 Bangle bearing found jam due to coolant & dust entry

2. Modify design of unit to avoid coolant entry Santosh 8th Oct 15

2 Bangle bearing failure frequently due to wrong fitment

2. Start clamping unit repair facility at our end Gopal 1st Oct 15

3 Lammelring fitment not done due to difficulty in fitment

1. Modify design of lamellring Santosh 15th Oct 15

4 Wrong judgment of operator for functionality of clamping unit

3. Make test rig in presetting for clamping unit checking

Shekhar 30th Oct 15

5 Coolant found inside cover plate which enters into bearing

1. Provide additional hole on cover plate Panse 15th Oct 15

Each PIC was assisted with separate teams from cross

functional including maintenance, engineering,

production and purchase

Action plan for solution implementation 4.1.4 Q1,

Q2

4.1.1 Q1,

Q2

SKF Six Sigma

26

© SKF Group

© SKF Group

Lammelring implementation

Slide 51

Lammelring

3.2.2 Q2


Need for design change

Bangle

Bearing

Early Bearing

failure due to

contamination of

grinding dust

SKF Six Sigma

27

© SKF Group

© SKF Group

Bangle Bearing

Lammelring

Coolant / Dirt Contamination

Design change of lammelring

Slide 53

3.2.2 Q2

Outer Ring ( Stationary )

Inner Ring ( Rotating )

© SKF Group

Contradiction solving

Lammelring Ring Outside

diameter

Big

Small

Wear & tear

Coolant flow

bock

No wear & tear

Coolant will flow

/ Damage

+ ve

- ve

+ ve

- ve

Inner Ring ( Rotating )

Outer Ring ( Stationary ) Lammelring Big

Lammelring Small

• Lammelring has to be Big to stop

coolant & dirt flow

• Lammelring has to be small to stop

relative motion impact

(ware & tear)

SKF Six Sigma

28

© SKF Group

© SKF Group

Bangle Bearing

Lammelring

Coolant / Dirt Contamination

Lammelring

No Contamination

Bangle Bearing

Functional Thinking

TRIZ

Before

After

Design change of lammelring

Slide 55

Solution

1

After

3.2.2 Q2

© SKF Group

In-house Repair Process Establishment


Setup Development

Skill Development

Process Development

Slide 56

Solution

2

3.2.2 Q2

SKF Six Sigma

29

© SKF Group

© SKF Group

To eliminate requirement of skill for clamping unit inspection, test rig

developed outside machine in presetting department

Test rig development in presetting


Solution

3

Arrangement

similar to

machine

Clamping unit

Artificial spindle

inside clamping

unit for checking

Before After

No test rig

Clamping unit

test rig

Slide 57

3.2.2 Q2

© SKF Group

Actions - Bangle bearing – Eliminate failure

due to lubrication missing

• Greasing Process Started

• Cleaning Process Started

• Small Correction Started

Slide 58

Solution

4

4.2.1 Q1 3.2.2 Q2

SKF Six Sigma

30

© SKF Group

© SKF Group

Validation for actions taken -

Bangle bearing

Week # Units BB ReplacedGreasing

done

Cleaning and

greasing done

Small

correction in

Wk 40 32 2 4 19 7

Wk 41 28 0 3 19 6

Wk 42 28 3 5 13 7

Wk 43 44 3 8 25 8

Wk 44 34 4 6 13 11

Wk 45 23 1 6 12 4

Wk 46 22 1 8 8 5

Wk 47 18 1 2 10 5

Wk 48 29 2 7 16 4

Wk 49 27 1 6 15 5

Small

corr

ectio

n in

spar

e

Cleani

ng a

nd g

reas

ing d

one

Greas

ing d

one

BB Repl

aced

30

25

20

15

10

5

0

Dat

a

Box Plot of New Process

Data Collection

Annova

Annova Plot

There is impact of other process on Clamping

unit repair process

No complaint from customer for any failure

Slide 59

Annova Objective : To verify contribution

of newly introduced process

3.2.3 Q1,

Q2

3.2.5 Q1,

Q2

© SKF Group

Result - Bangle bearing

Consumption Reduction by 78 %

Cost Reduction by 81 %

Slide 60

4.3.1 Q1,

Q2

SKF Six Sigma

31

© SKF Group

© SKF Group

Clamping unit Cost

16.8 MINR

Spar Cost

12.2 MINR

Repairing Cost

4.6 MINR

Bangle Bearing

9.6 MINR

Step Seal

2.4 MINR

Approach

Challenging Life

Challenging Cost

Approach

Challenging Life

Challenging Cost

DMAIC

TRIZ DMAIC

Slide 61

© SKF Group

Step seal

set-1 Step seal

set-2

Step seal

set-3

Step Seal

Slide 62

SKF Six Sigma

32

© SKF Group

© SKF Group

Step seal

set-1

Step seal

set-2

Step seal

set-3

Step Seal

• Total 3 seal+ ”O” rings are used in single

unit

• Average cost of single set is around Rs.

25800 (Max. Rs. 86784 & min. Rs. 6072)

• Very delicate rubber seals

• Eliminate leakage in bearing and provides

smooth movement

Step seal

Slide 63


Fish bone diagram for causes identification for

Step Seal failure & cost increase -


Step seal

failure

MAN MACINE METHOD

MANAGEMENT MOTEHR

NATURE MATERIAL

Damage of step

seal during

mounting

Step seal with “o”

ring not standard in

store, only step seal

and piston seal I

standard

Step seal and “O”

ring not

manufactured

together

No SOP for

removal and

mounting

Major dash on

machine to

clamping unit

Damage of step

seal during dis

mounting

High cost of seal

due to import

Damage of seal

mounting guides

Operator mistake

during

mounting/dis

mounting

Slide 64

Atmospheric

temperature and

moisture can

change properties of

seal material

2.2.1 Q1 &

Q2

SKF Six Sigma

33

© SKF Group

© SKF Group

Six Sigma Cause & Effect Matrix

1 2 3

Rating of Importance to

Customer10 7 10

Key Process Outputs

Ste

p s

eal lif

e

Cost of serv

ice

Qualit

y o

f

cla

mpin

g u

nit

Process Step Process Input Total

1Step seal w ith “o” ring not standard in store,

only step seal and piston seal I standard9 9 9 243

2Step seal and “O” ring not manufactured

together9 9 9 243

3 Damage of seal mounting guides 9 9 9 243

4Damage of step seal during

mounting/dismounting9 3 9 201

C&E Matrix & FMEA for Step Seal

C & E Matrix FMEA

• Step seal with “o” ring not standard in store, only step seal and piston seal

standard

• Step seal and “O” ring not manufactured together

• Damage of seal mounting guides

• High cost of step seal

Slide 65

3.1.2 Q1 2.3.2 Q1,

Q2, Q3

2.3.1 Q1 &

Q2

© SKF Group

Final Solutions – after team discussion

based on criteria based Matrix

1Step seal with “o” ring not standard in store,

only step seal and piston seal standardStandardize all types of seals in store

2Step seal and “O” ring not manufactured

togetherLocalized manucturing of step seal in set with "O" ring

3 Damage of seal mounting guides Start clamping unit repair facility at our end

Localization of seal manufacturing in SKF, Pune seal

manufacturing

Condition based maintenance of step seal

Team Meeting subject : Finalization of solutions / ideas for improing Step Seal life

Present Members : GDS, ULR, SP, SB, AP, AZ, SM

Sr. no. Causes Final solutions to eliminate cause

4 High cost of step seal

Slide 66

3.1.2 Q1,

Q2 & Q3

3.1.1 Q1 2.3.2 Q3

3.2.1 Q1,

Q2 3.1.1

Q1, Q2

2.4.1 Q2 2.3.3

Q1, Q2

3.2.2 Q1,

Q2

SKF Six Sigma

34

© SKF Group


Probable difficulties in implementation of

solutions

Slide 67

Sr. no. Final solutions to eliminate cause What can go wrong in implementation Action PIC Date of completion

1 Standardize all types of seals in store Inventory cost will increase Discard old step seals, localization will help to reduce cost

Santosh 29th Sept

2 Localized manucturing of step seal in set with "O" ring

Supplier capability to manufacture such delicate parts

Assistance to supplier for setting manufacturing process and tolerance

Panse 30th Oct

3 Start clamping unit repair facility at our end

Availability of skilled operator To make diploma trainee available in channel T5 & spare Mr. Panse

Hemant 23rd Sept

Compatibility of reapir of clamping unit to opeator

Give training on details of drawing and at supplier end to Mr. Panse

Gopal 28th Sept

Availability of place and equipment To make list of required equipmant and make them available

Gopal 25th Sept

4 Localization of seal manufacturing in SKF, Pune seal manufacturing

Supplier capability to manufacture such delicate parts

Assistance to supplier for setting manufacturing process and tolerance

Panse 30th Oct

Drawings of all step seal with specification not available

Engineering to prepare drawing from present available seal

Pratik 10th Oct

Suitability of local manufactured seals to existing clamping units

Spare one clamping unit of each type and provide to supplier for checking fitment

Panse 10th Oct

5 Condition based maintenance of step seal

- - - -

Black Hats

4.1.3 Q1,

Q2

4.1.2 Q1,

Q2 & Q3

3.3.1 Q3


Each PIC was assisted with separate teams

from cross functional including maintenance,

engineering, production and purchase

Action plan for solution implementation

Sr. no. Causes Final solutions to eliminate cause PIC Target date

of completion

Actual date of

completion Status

1 Step seal with “o” ring not standard in store, only step seal and piston seal standard

Standardize all types of seals in store Santosh 1st Oct 15

2 Step seal and “O” ring not manufactured together Localized manufacturing of step seal in set with "O" ring

Gopal + Panse

1st Dec 15

3 Damage of seal mounting guides Start clamping unit repair facility at our end Gopal 1st Oct 15

4 High cost of step seal

Localization of seal manufacturing in SKF, Pune seal manufacturing

Gopal + Panse

1st Dec 15

Condition based maintenance of step seal Panse 5th Oct 15

4.1.4 Q1,

Q2

4.1.1 Q1,

Q2

SKF Six Sigma

35

© SKF Group

© SKF Group

Actions - Step Seal Local Supplier

Development

Imported

Step Seal

Drawing

understanding

( Function)

Local Supplier

Developed

Trial

Lot Corrections

Local Supply

Started

Unit Cost Before – Max. Rs. 86784,

Local Supplier Cost – Max. Rs. 5000

Consumption per Year – @ 94 Step Seals , Cost Impact Per Year – 1.2 MINR

>80 %

Cost

Reduction

Slide 69

3.2.2 Q2

© SKF Group

Actions - Step Seal – Condition based

maintenance

• Condition based replacement of

component

• Localization of imported step

seal

• Seal and O-ring manufacturing

in set

Slide 70

4.2.1 Q1 3.2.2 Q2

SKF Six Sigma

36

© SKF Group

© SKF Group

Validation - Step Seal

There is significant reduction in clamping unit repair after changing the seal

Slide 71

3.2.3 Q1,

Q2

3.2.5 Q1,

Q2

20151050

X_

Ho

Differences

Boxplot of Differences(with Ho and 95% t-confidence interval for the mean)

© SKF Group

Result - Step Seal

Consumption Reduction by 94 %

Cost Reduction by 96 %

Slide 72

4.3.1 Q1,

Q2

SKF Six Sigma

37

© SKF Group

© SKF Group

Clamping unit Cost

16.8 MINR

Spar Cost

12.2 MINR

Repairing Cost

4.6 MINR

Bangle Bearing

9.6 MINR

Step Seal

2.4 MINR

Other

0.2 MINR

Outsource

Process

Approach

Challenging Life

Challenging Cost

Approach

Challenging Life

Challenging Cost

Approach

Challenging Life

Challenging Cost

DMAIC

TRIZ DMAIC Lean

Slide 73

© SKF Group

In-house Repair Process Establishment


Setup Development

Skill Development

Process Development

Slide 74

3.2.2 Q2

SKF Six Sigma

38

© SKF Group

© SKF Group

Clamping Unit Repair in Spindle Services

Noise from Bearing Clamp / Declamp

Problem

Remove Bearing

Clean it with white

spirit

Fill grease in bearing

Assemble unit

Check

Seal

Dismantle Unit

Clean

Assembly

Put Repaired

Tag

Return to Store

Ok

Not Ok

Replace Seal

Assembly

Put Repaired

Tag

Return to Store

Broken / weak /

damage

Replace with new

bearing

Return to Store

Axial

Play

Not Ok

Ok

New Process

Slide 75

4.2.1 Q1,

Q2

3.2.2 Q2

© SKF Group

Clamping unit Cost

16.8 MINR

Spar Cost

12.2 MINR

Repairing Cost

4.6 MINR

Bangle Bearing

9.6 MINR

Step Seal

2.4 MINR

Other

0.2 MINR

Outsource

Process

Approach

Challenging Life

Challenging Cost

Approach

Challenging Life

Challenging Cost

Approach

Challenging Life

Challenging Cost

DMAIC

TRIZ DMAIC Lean

Slide 76

SKF Six Sigma

39

© SKF Group

© SKF Group

2015 Baseline – Total Clamping unit spares +

Repair cost / Month

Total Cost

Before 1.4 MINR / Month


87 % Reduction

Target

0.98 MINR / Month

Actual

0.18 MINR / Month

Spares Cost



85 % Reduction

Repair Cost



93 % Reduction

Slide 77

4.3.1 Q1,

Q2

© SKF Group

Understanding Process

Identification critical Inputs

Validation of critical inputs

Developing Standers

Skill Development

Slide 78

SKF Six Sigma

40

© SKF Group

© SKF Group

Data Collection For Quality of Clamping Unit


Description

TRB Bangle

bearing

Clamping Unit

TRB

Conventionals

Clamping Units.

HBU Bangle

bearing

Clamping Unit

HBU

Conventionals

Clamping Units.

Total clamping

units repaired

per month

Jan-15 47 32 3 7 89

Feb-15 85 27 2 4 118

Mar-15 59 50 3 12 124

Apr-15 116 84 8 16 224

May-15 52 60 7 10 129

Jun-15 105 59 7 16 187

Jul-15 86 90 7 18 201

Aug-15 72 53 12 10 147

Sep-15 60 40 26 8 134

Sr. Description of spindle/unit Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Total Sp.

no repaired

Sub Total 10 10 11 8 3 6 2 8 2 4 9 2 75

H Measuring Gauges & Spindles

46 Thruvar 7 3 9 2 1 4 3 3 2 3 2 4

47 Thruvar05 6 2 2 0 2 3 3 3 5 2 4 3

48 Megars 5 3 2 0 2 2 1 1 0 1 3 5

49 Mini Thruvar 0 0 0 0 2 0 8 1 1 0 1 0

Idmar/Unimar 1 2 1

Sub Total 18 8 13 2 7 10 15 10 8 6 11 12 120

I Precision Brg. Clamping Units

50 SGB/SGF/SFF/Famir Clamping Unit 4 4 7 4 5 12 4 2 7 3 1 8

51 SFP Clamping Unit 5 1 1 3 0 2 3 3 3 2 6 1

52 Bangle bearing Clamping Unit 47 85 59 116 52 105 86 72 60 22 10 0

New FBM CL. Units 0 0 0 0 1 0 1 0 0 0 0 4

Sub Total 56 90 67 123 57 119 94 77 70 27 17 13 810

J Conventionals Clamping Units. 32 27 50 84 60 59 90 53 40 11 0 3

Sub Total 32 27 50 84 60 59 90 53 40 11 0 3 509

K Ring Loaders 12 2 6 3 5 2 4 2 4 2 4 3

Sub Total 12 2 6 3 5 2 4 2 4 2 4 3 49

M Other 40 30 30 30 40 40 40 32 30 30 25 25

Spindle Hotel charges

Total 151 149 180 240 144 220 218 165 141 68 60 54

Total no of Spindle repaired per month

Slide 79

© SKF Group



Problem

Remove Old Bearing

Mount New Bearing

Assemble Clamp

Unit

Put Repaired

Tag

Return to Store

Check

Seal

Dismantle Unit Dismantle Unit

Check for Dirt / Dust

Clean

Assembly

Put Repaired

Tag

Return to Store

Clean

Assembly

Put Repaired

Tag

Return to Store

Ok

Not Ok

Replace Seal

Assembly

Put Repaired

Tag

Return to Store

Broken / weak /

damage

Old Process

• Current Process

is outsourced

• All Critical factors

are Noise

• In-house process

Slide 80

SKF Six Sigma

41

© SKF Group

© SKF Group



Problem

Remove Bearing

Clean it with white

spirit

Fill grease in bearing

Assemble unit

Check

Seal

Dismantle Unit Dismantle Unit

Check for Dirt / Dust

Clean

Assembly

Put Repaired

Tag

Return to Store

Clean

Assembly

Put Repaired

Tag

Return to Store

Ok

Not Ok

Replace Seal

Assembly

Put Repaired

Tag

Return to Store

Broken / weak /

damage

Replace with new

bearing

Return to Store

Axial

Play

Not Ok

Ok

New

Process

New

Process

Old Process

What Changed

78 %

Reduction

100%

Lamellring

implemented

Process

Trimmed

Slide 81

3.2.2 Q2

© SKF Group

Quality - Result


Clamping unit Repaired is reduced by 29 %

153 per month to 109 per month

Slide 82

4.3.2 Q1,

Q2 & Q3

SKF Six Sigma

42

© SKF Group

© SKF Group

Data collection

Identification of critical inputs

Validation of critical inputs

Design of experiments

Setup chart updating

Slide 83

© SKF Group

Data Collection For Lost Hrs due to Clamping Unit


Channels 2015

T8IR 147

T7 101

T6 18

T3 16

T1S 15

T2 13

T4 10

HBU1-1 5

HBUT 1

Grand Total 326

Per Month lost Hrs 27

Month - 2015Lost Hrs Due to

Clamping Unit

Jan 75

Feb 43

Mar 21

Apr 12

May 20

Jun 15

Jul 14

Aug 17

Sep 22

Oct 45

Nov 21

Dec 20

326

Channel DT Code Description Date Month Year DT. Hrs. Reasons

T1S 5134 TOOLS 05/01/2015 Jan 2015 1.0 Clamping unit change

T1S 5134 TOOLS 13/01/2015 Jan 2015 4.5 STI Clamping unit NA

T1S 5134 TOOLS 16/12/2015 Dec 2015 7.0 FBM clamping unit NW

T1S 5134 TOOLS 17/12/2015 Dec 2015 2.9 FBM Clamping unit prob

T1S 5135 MECHANICAL 10/10/2015 Oct 2015 2.0 ABG clamping cyll rod broken

T2 5134 TOOLS 20/04/2015 Apr 2015 4.0 Clamping unit prob

T2 5134 TOOLS 23/07/2015 Jul 2015 1.6 Clamping rod prob

T2 5134 TOOLS 17/08/2015 Aug 2015 1.5 Clamping unit vkr change

T2 5134 TOOLS 07/10/2015 Oct 2015 0.8 SHD clamping unit change

T2 5135 MECHANICAL 19/03/2015 Mar 2015 0.5 Clamping air leakage from valv

T2 5138 M/C ADJUSTMENT 30/01/2015 Jan 2015 1.3 Clamping unit change 1267

T2 5138 M/C ADJUSTMENT 25/07/2015 Jul 2015 1.8 1267 Clamping unit prob

T2 6115 Waiting for Spindle 13/03/2015 Mar 2015 0.7 SGF clamping unit NA

T2 6115 Waiting for Spindle 21/04/2015 Apr 2015 2.0 Clamping unit NA

T3 5134 TOOLS 31/01/2015 Jan 2015 0.5 SHG Clamping unit NA

T3 5134 TOOLS 11/02/2015 Feb 2015 1.5 STB Clamping unit Prob

T3 5134 TOOLS 06/11/2015 Nov 2015 5.9 SFP clamping unit change

T3 5135 MECHANICAL 14/10/2015 Oct 2015 2.5 SHG Clamping unit jam

T3 5135 ELECTRICAL 05/09/2015 Sep 2015 0.8 SHG clamping prob

T3 5138 M/C ADJUSTMENT 10/01/2015 Jan 2015 0.2 SFP Clamping unit Prob

T3 5138 M/C ADJUSTMENT 14/01/2015 Jan 2015 3.0 Clamping unit vibr prob

T3 5138 M/C ADJUSTMENT 22/08/2015 Aug 2015 1.2 SFP clamping unit air pipe

T3 5138 M/C ADJUSTMENT 05/09/2015 Sep 2015 0.7 SGB Clamping plate bolt broken

T4 5134 TOOLS 08/01/2015 Jan 2015 4.5 SHD 1344 Clamping unit NA

T4 5134 TOOLS 18/04/2015 Apr 2015 2.0 Clamping unit NA

T4 5134 TOOLS 03/06/2015 Jun 2015 3.0 Clamping unit NA

T4 5134 TOOLS 09/09/2015 Sep 2015 0.5 Clamping unit NA

T6 5134 TOOLS 28/01/2015 Jan 2015 1.5 SGC Clamping unit failure NA

T6 5134 TOOLS 13/07/2015 Jul 2015 9.1 Clamping unit NA

T6 5134 TOOLS 16/09/2015 Sep 2015 3.0 SGC clamping plate change

T6 5134 TOOLS 23/09/2015 Sep 2015 1.0 Clamping plate of pbk NA

T6 5134 TOOLS 16/10/2015 Oct 2015 1.7 Clamping unit plate change

T6 5134 TOOLS 29/10/2015 Oct 2015 1.2 Clamping unit change 556SHD

T6 5134 TOOLS 03/11/2015 Nov 2015 1.3 RTSB Clamping plate NA

T6 5134 TOOLS 17/11/2015 Nov 2015 3.3 clamping plate NA

T6 5134 TOOLS 18/11/2015 Nov 2015 2.0 Clamping plate prob

** TRB Loss Hours 2015 **

Slide 84

SKF Six Sigma

43

© SKF Group

© SKF Group

Actions – Down Time


• All clamping units which were lying idle from long time due to non

availability of spares, made ready for use

• More clamping units ordered to make available spare units.

• Lead time of unit repair reduced.

• For preset clamping unit, in-house test rig started to inspect

• Weekly audit of clamping unit lubrication health started including

CLIT sheet

Slide 85

3.2.2 Q2

© SKF Group

Design of Experiments Improve Machine

parameters to improve Clamping unit life


Critical Inputs on M/c

• Air Pressure

• Lubrication drops per minute

• Clearance in ring and clamping

unit

Output

No. of Bearings produced

Slide 86

3.2.3 Q1 &

Q2

SKF Six Sigma

44

© SKF Group

© SKF Group

Results – Down Time


Back

Clamping unit Repaired is reduced by 29 %

26 per month to 18 per month

Slide 87

4.3.2 Q1,

Q2 & Q3

© SKF Group

Result

Cost

Before 16.8 MINR / Annum

After 2.2 MINR / Annum

87 % Reduction

Quality - Repair

Before 1844 No / Annum

After 1279 No / Annum

29 % Reduction

Down-Time

Before 319 Hrs / Annum

After 226 Hrs / Annum

29 % Reduction

Slide 88

4.3.1 Q1,

Q2

4.3.2 Q1,

Q2 & Q3

SKF Six Sigma

45

© SKF Group

© SKF Group

Result : Clamping unit cost % wrt

VACS

Avg. Clamping unit cost % wrt

VACS

Before = 0.98 % Now = 0.16 %

Standard deviation

Before = 0.23 % Now = 0.06 %

• Practical implication : Profitability is increased by @

1 % to all the products for particular business unit.

• Predictability of clamping unit cost is increased by

74 %

Slide 89

4.3.1 Q1,

Q2

© SKF Group


Quality Cost Channel

Down Time

Spars Cost Repair Cost

Bangle Bearing Step seal

Life Increase

In house repair

DMM / History Card /

Failure analysis

Repaired non

moving/used units

New clamping units

procured

Reduced repair lead

time

Skilled operator

deployed

Clamping unit test rig

implemented

Standards

developed

In h

ou

se

re

pa

ir

• Implement 100% lamellring

• Grease filling

• Re use bangle bearings

• Lubrication system audit started

Cost per unit Life Increase

• Changed

damaged parts

• Handling

improved

Cost per unit

• Localization

done

• Drawings

modified for

better fitment

No of Units

Reduction

by 29 %

Cost

Reduction

by 87 %

Down Time

Reduction

by 29 %

Total savings 1.5 Cr

Replication potential – 3.2 Cr

Slide 90

4.3.1 Q1,

Q2

SKF Six Sigma

46

© SKF Group

© SKF Group

Process StepWhat's

Controlled?

Input or

Output?Spec. Limits / Requirements

Measurement

Method

Control

MethodSample Size Frequency Who/What Measures

Where

Recorded

Decision Rule/

Corrective ActionSOP #

Repair of bangle bearing

clamping unit

Consumption of

step sealInput No damage or brakage of seal Visual S.O.P. 100% Every unit Operator from presetting History sheet

When Action - If seal damaged/broken

What Action - Replace

BB Clamping unit

repair SOP

Repair of bangle bearing

clamping unit

Consumption of

bangle bearingInput No dirt/dust, axial play in bearing Visual, by hand S.O.P. 100% Every unit Operator from presetting History sheet

When Action - If seal damaged/broken

What Action - Replace

BB Clamping unit

repair SOP

Repair of conventional

clamping unit

Coolant entry in

ballsOutput

No exposure of balls when unit in

clamp conditionVisual S.O.P. 100% Every unit Operator NA

When Action - If after clamping stroke

completion balls of unit exposes

What Action - Replace stopper with lesser

width or replace ring

Conventional clamping

unit repair SOP

Fitment of lamellring in

bangle bearing clamping unit

Coolant entry in

bangle bearingInput

Tow lamellring fitted (One on

piston and other on collar)Visual Drawing 100% Every unit Operator NA

When Action - If laellring not entering in

slot

What Action - Replace either collar or

piston

Bangle bearing unit

assembly drawing

Ordering of step seal

Local SKF make

lammelring to

order

InputTo order it from local SKF

distributor only to save costVisual / item number Drawing 100% Every seal set Grinding store and purchase System

When Action - Step seal not in stock in

stores

What Action - Ordering of seal set from

local SKF distributor

Step seal drawing

Repair of bangle bearing or

conventional clamping unitRepair locaiton Input

To be repaired in TRB Presetting

onlyNA S.O.P. 100% Every unit Grinding store operator NA

When Action - Whenver for repair clamping

unit come to grinding store

What Action - Hand over it to operator in

TRB preseting responsible for unit repair, if

he is absent, then consult with Presetting

supervisor and take appropriate action

SOP for unit repair

handover

Control Plan

Summary

• 3 SOPs / Process developed

• One drawing modification

• CLIT modified

• History card and cl unit unique numbering system developed

• Weekly lubrication health audit started

Slide 91

5.1.2 Q1,

Q2

5.1.1 Q1,

Q2

© SKF Group

Standards created -


Process Flow for Bangle bearing clamping unit repair

Bangle bearing clamping unit for repair

Check attached tag for functional problem

Unit jam in rotation, clamp-declamp not

working, noisy

Dismantle unit

Change seal set

Check for dirt/dust or traces of coolant

Check for cause of coolant, dirt/dust

Check seal for any damages, crack,

etc.

Check for any sharp edge,

damage or wear in body, piston and

cover(cap)

Check bangle bearing for noise, jam rotation and

axial play

Check unit for freeness of rotaion,

clamp/declamp stoke working

Reapir according to problem mentioned in tag

Remove sharp edge, damage through filing, if

not possible, change it

Yes

No

Yes

No

Eliminate cause(On m/c or in unit)

No

Yes

Take out bangle bearing, clean it with clean white

spirit and brush thorughly

Clean all components in clean whilte spirit

Yes

No

Yes

No

Assemble all components as per drawing

Attach white tag of work completion

Return clamping unit to grinding store

END

START

No

Yes

SOP for clamping unit repair

Sr. no. Date Problem Observed Action Spares consumed Remark

Clamping Unit Service History Card

Type of unit : Conventional / Bangle Bearing Number :

Service history card

TRB PresettingClamping unit repair location

Factory

Resetting Grinding Store

Ch

ann

el

M/c

General Store

Repair

Unit for Repair

Repaired Unit

Filed unit submit to GRD store

Good Unit for use to channel

Failed Unit

Spares Received

Spares Request

Clamping unit service process flow

Drawing modification

Slide 92

5.1.2 Q1,

Q2

5.1.1 Q1,

Q2

4.2.1 Q2

SKF Six Sigma

47

© SKF Group

© SKF Group

Project Replication


Taper Roller Bearing

unit

(TRB)

Deep Groove Ball

Bearing Unit

(DGBB)

HBU Manufacturing

unit

(HBU)

Project completed in TRB & HBU, replication plan in process for DGBB

© SKF Group

Project Closing meeting


• Project leader, sponsor, financial

controller, team members, process

owner and stakeholders present

• Project leader explained project

presentation with results

• Team feedback & experience shared

• Formal project closing declared by

sponsor

5.2.1 Q1

SKF Six Sigma

48

© SKF Group

© SKF Group

© SKF Group

Noise to Controllable

Contradiction solving

Prior action

DMAIC thinking

TRIZ thinking

Lean thinking

In-house repairing

Addition of seal

Test rig development

Quality 29% improvement

Cost 87 % Reduction

Delivery - DT

reduction

29%)

DOE

Business - Profitability increased by 1% to all Products (1.5 cr Savings)

Customer - Reliability loss reduction by 33 %

Actions Approach Method Impact

Scope - Entire Factory

Thank You

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