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 designExtra Bond on AV 9000 Outer Why WhyWhy WhyWhyAnalysis AnalysisOuter surface area wasnt properly maskedWhy Three was no cover at the sidesWhy Improper Fixture Design Wrong Method Wrong Method Why used usedConclusion:Wrong method have been used for Bonding on AV 9000 outer. TRELLEBORG GROUP37 38. Developing the Solution& Feasibility Study Tools:Knowledge Skills Experience Team SpiritTRELLEBORG GROUP 39. Feasibility Study We have used wrong method of Bonding. Manual mode has to beavoided. Trial had been taken on Existing Rotary machine (Full Auto) There were no extra bonds on outer faces & collar on AV 9000 after trailrun OK PartsPart has to be fixed into the Fixtures on rotary Machine TRELLEBORG GROUP39 40. Solution Development Existing Fixtures have key-chuck & it takes extra time for setting change Parts fixed into the fix diameter fixtures on Rotary MachineBEFOREAFTERHave key-chuck Fix-chuck TRELLEBORG GROUP40 41. Foreseeing Problem of ResistanceTRELLEBORG GROUP 42. Foreseeing ProblemsSL.Possible ProbableStatus againstProposed Root CauseNo.Solutions Resistance ResistanceSolutionNot agreed by Parts should beCycle time / part Industrial Clamp parts intoclamped such aImproper Fixturehas been Engineering1 the fixtures onway that 3 partsDesignincreased to 11 department asRotary can be clampedsec. from 6 sec. cycle time hasverticallybeen increased TRELLEBORG GROUP42 43. Trial Implementation &Check PerformanceTRELLEBORG GROUP 44. Trial Implementation Proposed Solutions SL. Possible / Proposed Trial Results Conclusion No. Solution ImplementationThe lower most partwasnt properly Fixtures should be Clamps made such abonded. But The made such a wayClamp parts into the way that 3 outer can1 upper one & that 2 outer parts fixtures on Rotary be fixed in one medium part were can be bonded fixture verticallyuniformly bonded asuniformlyper specification44 45. Cycle Time Observation during Trial ImplementationManual BondingFixtures with key chuckFixtures with fixed chuck OperationTime (sec)Operation Time (sec) OperationTime (sec)Loading30 Primer / Bond 11Primer / Bond11Primer 45 Setting change5 Bond50Unloading25Total CycleTotal Cycle Total Cycle150 16 11 Time TimeTime Parts / fixture 25 Parts / fixture 1 Parts / fixture 1Cycle Time / Cycle Time / Cycle Time / 616 11part (Outer) part (Outer) part (Outer) 3 parts clamped in one fixture 2 parts clamped in one fixtureOperationTime (sec)Operation Time (sec) Primer / Bond11 Primer / Bond 11 Total Cycle Time 11Total Cycle Time 11 Parts / fixture 3 Parts / fixture 2 Cycle Time / Cycle Time /3.75.5 part (Outer) part (Outer) TRELLEBORG GROUP45 46. Action Plan Final Solution SL.Final Solution Target Date Responsibility Status No.Fixtures should bemade such a way Amit Solanki & 1that 2 outer parts15-Oct-12 Implemented Nishesh Tripathican be bonded uniformly TRELLEBORG GROUP46 47. Effectiveness Check after Implementing SolutionsRejection% of Extra Bond has dropped down to Zero percentage Overall Rejection cost on October12 has been reduced 92.67% than September 12 TRELLEBORG GROUP47 48. Regular ImplementationTRELLEBORG GROUP 49. Standardization of Action SL.DescriptionWhat Where When Who Status No.Changes in Process 1Process PFD15-Oct-12 IEDoneFlow DiagramFailure Mode analysis 2 for the modifiedFailure Mode AnalysisPFMEA15-Oct-12 IEDone process step 3 Changes in Control Plan Process SheetControl Plan 15-Oct-12QualityDoneOnline Inspection (Viscosity & DFT) in 4 Rotary for AV 9000 Inspection SheetRotary 15-Oct-12QualityDone outer instead of Bonding boothDetailed modified 5 One Point Lesson (OPL) Rotary 15-Oct-12 IE, Process Done processWork Instruction forStandard Operating 6Rotary 17-Oct-12 IEDonethe modified processProcedure (SOP)OK & NG Sample to be 7 OK & Not-OK PartsRotary 17-Oct-12QualityDone kept TRELLEBORG GROUP49 50. Review of Activity Chart ~ Plan v/s ActualQUALITY CIRCLE NAME DEPARTMENTFACILITATORMEMBERPRAYAAS METAL PREPARATION SAMBIT SAHALEADER: MUNIRAJ PROJECT REASON FOR SELECTION Extra Bond on AV 9000 Outer To reduce Rejection Percentage on AV 9000 Outer MEMBER: PRADEEP JHA MEETING DAY & TIME DATE OF BEGINNINGDATE OF COMPLETIONMEMBER: INDERJIT MEMBER: TARUN KUMARFriday, ( 2 PM to 4 PM) 01-Jul-1230-Oct-12 MEMBER: NEHA ARORAA P July 12 August 12September 12October 12 Sl. No.Activity Week StatusC D 1 23 4 12 3 4123 41 2341 IDENTIFICATION OF PROBLEM2SELECTION OF PROBLEM PLAN3 DEFINE THE PROBLEM4 ANALYSE THE PROBLEM5 IDENTIFICATION OF CAUSE6 FINDING OUT THE ROOT CAUSEDO7DATA ANALYSIS8DEVELOPING THE SOLUTION9FORESEEING PROBLEM OF RESISTANCECHECKTRIAL IMPLEMENTATION & CHECK 10PERFORMANCE 11REGULAR IMPLEMENTATIONACT 12 FOLLOW UP & REVIEW TRELLEBORG GROUPPLANACTUAL DELAYED50 51. Follow Up & ReviewTRELLEBORG GROUP 52. Review of Monthly Rejection Trend Rejection Percentage of Extra bond has been dropped down to Zero (0) percent Overall Rejection cost on October12 has been reduced 92.67% than September 12 TRELLEBORG GROUP52 53. Review of Rejection Contribution Analysis 96 100 800 10091 8476 600 677557 400 4650 Before Q R31 y e t j 255 % m C u e v a t i l 200 25 12092 82 78 66 54 45 30 0 0 0 9 V A 4 6 0 V A0560VA 1 4 1 2 V A512VA 0 4 5 1 V A0052VA 0 4 3 1 V A0920VA 10095 100 8777 754006652 50 37 Q R y e t j200 After % m21 C u e v a t i l 120 25 92 82 78 66 54 45 3000 0 4 6 0 V A 0 5 6 0 V A1412VA 1 5 1 2 V A0451VA 0 0 5 2 V A0431VA 0 9 2 0 V ATRELLEBORG GROUP 54. Benefits : Tangible1. Quality Improvement: Rejection % of Extra bond reduced to 0% from 2.52%2. Productivity Improvement: Gross Production / shift has been increased to 4000 nos. to 4364nos. per shift3. Cost Saving: Rejection cost has been reduced to Rs. 1057/- from Rs. 32630/-4. Customer Concern: Internal customer is happy TRELLEBORG GROUP54 55. Benefits : Intangible Improved problem solving skills of operators. Boost up the confidence level. Improved shop floor employees participation. Two more Quality Circle team have come up within one month. Improved Team work Developed positive attitude towards work and company. TRELLEBORG GROUP55 56. Horizontal Deployment The same fixture modification can be done on AV 2141 outer, AV 2151 outer, AV 2091 outer, AV 1340 outer AV 2141 AV 1340 AV 2091 AV 2151 TRELLEBORG GROUP56 57. Next QCC TargetExtra Bond in AV 0640B InnerTRELLEBORG GROUP 58. Thought of Prayaas TeamTRELLEBORG GROUP 59. TRELLEBORG GROUP