Quality circle 'prayaas' - 2012

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  • 1. Trelleborg AutomotiveQuality Circle Pryaas

2. Trelleborg Automotive India Pvt. Ltd ISO 14001 OHSAS 18001 TS 16949 ISO 50001 Ford Q1 100 % subsidiary of Trelleborg AB, SwedenTRELLEBORG GROUP 3. Business Area of Trelleborg GroupTRELLEBORG GROUPTRELLEBORG AUTOMOTIVE 4. Trelleborg Automotive Biggest Non-Tyre Rubber Player Founded in 1905 Employing 20,000 peopleTRELLEBORG GROUPTRELLEBORG AUTOMOTIVE 5. Trelleborg AutomotiveTRELLEBORG GROUPTRELLEBORG AUTOMOTIVE 6. Our Product PortfolioTRELLEBORG GROUPTRELLEBORG AUTOMOTIVE 7. Enhanced Global Footprint 130 Plants, 40 CountriesGlobal Design, Local SupplyTRELLEBORG GROUP TRELLEBORG GROUP 8. Our Customers North- Delhi area Hero Honda EicherLML West-MumbaiSwaraj Mazda Yamaha /Pune area Fiat DelhiHonda Siel CarsTrelleborg Plant Tata Cars Tata Trucks Daimler Chrysler GM Subaru EicherKolkataEast- Kolkata area Mahindra MumbaiTata Mahindra-Renault Hindustan Motors VW SkodaPune Audi South- Chennai/Bangalore area Toyota TVS Ford Ashok LeylandBangaloreGreen Color IndicatesVolvoRenault NissanTrelleborg India CustomersChennai HyundaiBMW Royal EnfieldTRELLEBORG GROUP 9. Our Manufacturing ProcessTRELLEBORG AUTOMOTIVERubber MixingTRELLEBORG GROUP9 October 2, 2008 10. Our Team - PryaasTRELLEBORG GROUP 11. SUMMARY QCC Name: Pryaas Quality Circle Started: July 2012 QCC Completed : October 2012 Meeting Scheduled : Once a week Meeting Day : Friday (2pm-4pm) No of Meetings planned: 16 No of Meetings conducted: 16 Attendance: 98%TRELLEBORG GROUP 12. Identification of WorkRelated Problem Tools:Brainstorming Problem Data BankTRELLEBORG GROUP 13. Problems Identified through problem data bank in Bond Application shop Major 09 Problems Identified Extra bond in AV 9000 outer - Category A Problem Extra bond in AV 0640 inner Category A Problem Extra bond in AV 0650 outer Category A Problem Extra bond in AV 2141 outer Category A Problem Extra bond in AV 2151 outer Category A Problem Extra bond in AV 1540 outer Category B Problem Extra bond in AV 2500 outer Category B Problem Extra bond in AV 1340 outer Category B Problem Extra bond in AV 0290 outer Category C ProblemTRELLEBORG GROUP 14. Selection of Problem Tools:Stratification Pareto Diagram BrainstormTRELLEBORG GROUP 15. Defect Categorizing Defect Categorizing The Problems are classified into the following categories:- Category A - This can be solved with minimum involvement of otherdepartment Category B - Involvement of other department required Category C - Management help is requirednBC zatio A riotegCaTRELLEBORG GROUP15 16. Stratification No ofABC tionCategory i za ProblemsCa tegor A5 B3 C11510 535 10mNbpoersfl. ABCTRELLEBORG GROUP 17. Major quality defects in Metal Preparation (Bonding)96 100 800 100 9184 76 60067 75 57 400 465031QRyetj 255 % m C u e v a t i l 200 25 120 92 82 78 66 54 45 3000 0 0 0 9 V A 4 6 0 V A 0 5 6 0 V A412VA 1 5 1 2 V A0451VA 0 0 5 2 V A0431VA 0 9 2 0 V ATRELLEBORG GROUP 18. We have selected this problem for QCCTRELLEBORG GROUP 19. Activity Chart QUALITY CIRCLE NAMEDEPARTMENT FACILITATOR MEMBER PRAYAASMETAL PREPARATION SAMBIT SAHALEADER: MUNIRAJPROJECT REASON FOR SELECTIONExtra Bond on AV 9000 Outer To reduce Rejection Percentage on AV 9000 OuterMEMBER: PRADEEP JHAMEETING DAY & TIMEDATE OF BEGINNING DATE OF COMPLETION MEMBER: INDERJIT MEMBER: TARUN KUMARFriday, ( 2 PM to 4 PM) 01-Jul-12 30-Oct-12MEMBER: NEHA ARORAA P July 12 August 12September 12October 12Sl. No.Activity WeekStatusC D 1 23 4 12 3 4123 41 234 1 IDENTIFICATION OF PROBLEM 2SELECTION OF PROBLEMPLAN 3 DEFINE THE PROBLEM 4ANALYSE THE PROBLEM 5 IDENTIFICATION OF CAUSE 6FINDING OUT THE ROOT CAUSEDO 7DATA ANALYSIS 8DEVELOPING THE SOLUTION FORESEEING PROBLEM OF 9 RESISTANCECHECK TRIAL IMPLEMENTATION & CHECK10 PERFORMANCE11REGULAR IMPLEMENTATIONACT12FOLLOW UP & REVIEW TRELLEBORG GROUP PLANACTUAL DELAYED19 20. Define the Problem Tools:Knowledge Skills ExperienceTRELLEBORG GROUP 21. Process Flow Sequence of Bonding on AV 9000 OuterBonding Fixture Primer Application Parts loading in fixture UnloadingDrying Bond ApplicationDryingTRELLEBORG GROUP 22. Extra Bond over AV 9000 outerExtraBondExtra bonding causes:1. Extra flash2. Part fitment problem (internal)3. Part fitment problem (customer) TRELLEBORG GROUP22 October 2, 2008 23. Analyse the Problem Tools:Graphs & ChartsTRELLEBORG GROUP 24. Observation & Data Collection for Rejection AnalysisTotalLoss in ValueMonthsRejection Qty % Rej. Target % Rej. Production(Rs.) January 12 31542876 2.78% 33215 0.50% February 1230546935 3.06% 34547 0.50% March 12 35476852 2.40% 32547 0.50%April 1234587785 2.27% 32580 0.50%May 1233658654 1.94% 32340 0.50%June 12 32598849 2.60% 31547 0.50% TRELLEBORG GROUP24 October 2, 2008 25. Rejection Analysis for Extra Bonding on AV 9000 outerIn part no. AV 9000 OUTER rejection was 2.51% from last four months dueto excess bond; leads to customer concernsThe rejection cost is approximate Rs. 32796/- per month. TRELLEBORG GROUP25 October 2, 2008 26. Identification of Cause Tools:Cause & Effect Diagram BrainstormTRELLEBORG GROUP 27. Cause & Effect Diagram MachineManNeedle Problem Wrong Bond Application Air PressureUnclean Gun Table ProblemVisual aids not clear Foreign ParticlesNo understanding of Gun Nozzle damaged Pressure gaugesMoisture inAirline Unskilled manpower Stirrer not working Wrong fixture used Material Pressure AV 9000 EXTRABOND Bond ViscosityImproper Fixture DesignImproper method Wet part unloading of sprayWrongMixing Spray distanceFixture Damage Wooden FixtureWrong quantity ofWrongVariation in thinnermaterial loaded quantityloadingWrong spray angleMaterialMethodTRELLEBORG GROUP 28. Finding out the Root CauseTools: Cause & Effect Diagram BrainstormTRELLEBORG GROUP 29. Gemba on Shop FloorSl. No. Probable CausesWho WhenWhereHow Qty.(Validated on 14thConclusion Checked ResultAug12) 1Wrong Bond ApplicationPradeep DFT test 10 pcs. All pcs found OkNot a cause 2Visual aids not clearTarunVisual Check-Clear & legible Not a causeNo understanding of pressure operators have clear 3Inderjit Sample question-Not a causegaugesknoledge 4 Unskilled operatorNehaSample Bonding10 pcs. All pcs found OkNot a cause 5 Wrong fixture used PradeepSample Bonding10 pcs. All pcs found OkNot a cause 6Air PressureInderjit Pressure Gauge10 pcs.Variation in 3 pcsProbable Cause 7Unclean GunTarunDFT test 10 pcs. All pcs found OkNot a cause 8Foreign Particles PradeepSample Bonding10 pcs. All pcs found OkNot a cause 9 Moisture in AirlineMunirajSample Bonding10 pcs. All pcs found OkNot a cause10Wooden fixtureMunirajSample Bonding10 pcs.Found Variation Probable Cause11 Stirrer not workingInderjit During Bond BondSample Bonding10 pcs. All pcs found OkNot a cause application Booth12Needle Problem Tarun Sample Bonding10 pcs. All pcs found OkNot a cause13 Table Problem NehaSample Bonding10 pcs. All pcs found OkNot a cause14 Materuial Pressure Inderjit Pressure Gauge10 pcs.Variation in 3 pcsProbable Cause15Gun nozzle damaged NehaSample Bonding10 pcs. All pcs found OkNot a cause16 Bond ViscosityNehaViscometeronce before bondingFound Variation Probable Cause17 Wrong Mixing PradeepSample Bonding10 pcs. All pcs found OkNot a cause18 Wrong quantity of thinnerMunirajSample Bonding10 pcs. All pcs found OkNot a cause Not possible to load19Wet part / wrong part loadingNeha Sample Check-Not a cause wrong parts20Wrong spray angle / distance TarunSample Check 10 pcs. All pcs found OkNot a cause21Improper Fixture Design TRELLEBORG GROUPMuniraj - - Found Variation Probable Cause29 30. Cause & Effect Diagram MachineManNeedle Problem Wrong Bond Application Air PressureUnclean Gun Table ProblemVisual aids not clear Foreign ParticlesNo understanding of Gun Nozzle damaged Pressure gaugesMoisture inAirline Unskilled manpower Stirrer not working Wrong fixture usedMaterial PressureAV 9000 EXTRABOND Bond ViscosityImproper Fixture DesignImproper method Wet part unloading of sprayWrongMixing Spray distanceFixture Damage WoodenWrong Fixture quantity ofWrongVariation in thinnermaterial loaded quantityloadingWrong spray angleMaterialMethodTRELLEBORG GROUP 31. Possible / Suspected Root Causes Air Pressure Material Pressure Bond Viscosity Wooden Fixture Improper Fixture Design TRELLEBORG GROUP31 October 2, 2008 32. Data Analysis Tools:Why Why Analysis BrainstormTRELLEBORG GROUP 33. Validation of Suspected Root Causes1. Rejection Data after change in Bonding Air Pressure Air PressureRejectedNo. of PcsOK Pcs Reasons(kg) Pcs104 9 010 4.59 1 Colour changed to Yellow10510 010 5.5 10 0106 9 1 Bond entered into the holeConclusion:No effect of changing in Air Pressure. This is not a Cause. TRELLEBORG GROUP33 34. Validation of Suspected Root Causes2. Trial Result on Bond Viscosity ViscosityNo. of Pcs OK Pcs Rejected Pcs Rejection (%) (sec) 50 2348 24% 50 2150 00% 50 1950 00% 50 1549 12%Conclusion:No effect of changing in Bond Viscosity. This is not a Cause. TRELLEBORG GROUP34 35. Validation of Suspected Root Causes3. Trial Result after change in Material Pressure MaterialNo. of Pcs Pressure OK Pcs Rejected Pcs Rejection (%) (kg/cm2) 501.5 50 00% 502.0 50 00% 502.5 50 00% 502.2 48 24%Conclusion:No effect of changing in Material Pressure. This is not a Cause. TRELLEBORG GROUP35 36. Validation of Suspected Root Causes4. Trial Result after changing the fixture material to NylonSide cover has been given &fixture material changed to NylonEliminates extra bond on side faces,but extra bond on collar continues Extra bond Conclusion: Changes in fixture material also gave the same kind (extra bond) of rejection. Theres a tendency of bent in Nylon fixture also,36 which leads to extra bond on side faces again on longer run. TRELLEBORG GROUP 37. Validation of Suspected Root Causes5. Unbalancing of plates during movement of material on conveyor andbonding because of improper fixture desig