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Trelleborg Automotive

Quality Circle – ’Pryaas’

TRELLEBORG GROUP

Trelleborg Automotive India Pvt. LtdTrelleborg Automotive India Pvt. Ltd

• ISO 14001• OHSAS 18001• TS 16949• ISO 50001• Ford Q1

• 100 % subsidiary of Trelleborg AB, Sweden

TRELLEBORG GROUP

Business Area of Trelleborg Group

TRELLEBORG AUTOMOTIVE

TRELLEBORG GROUP


Biggest Non-Tyre Rubber Player

Founded in 1905

Employing 20,000 people


TRELLEBORG GROUP



TRELLEBORG GROUP

Our Product Portfolio


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Enhanced Global Footprint

TRELLEBORG GROUP

Global Design, Local Supply

130 Plants, 40 Countries130 Plants, 40 Countries

TRELLEBORG GROUP

North- Delhi areaHero Honda EicherYamahaHonda Siel Cars

Trelleborg Plant

Delhi

Mumbai

Chennai

Bangalore

West-Mumbai /Pune areaFiatTata CarsTata TrucksDaimler ChryslerGMSubaruEicherMahindraMahindra-RenaultVWSkoda Audi

East- Kolkata areaTataHindustan Motors

South- Chennai/Bangalore areaToyota FordVolvoHyundaiRoyal Enfield

•TVS•Ashok Leyland•Renault Nissan•BMW

•LML•Swaraj Mazda

Pune

Kolkata

Green Color Indicates Trelleborg India Customers

Our Customers

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9 October 2, 2008


Rubber Mixing

Our Manufacturing Process

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Our Team - Pryaas

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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%

SUMMARYSUMMARY

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Identification of Work Related Problem

Tools: Brainstorming Problem Data Bank

TRELLEBORG GROUP

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 Problem

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Selection of Problem

Tools: Stratification Pareto Diagram Brainstorm

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Defect Categorizing Defect Categorizing

The Problems are classified into the following categories:-

Category A - This can be solved with minimum involvement of other department

Category B - Involvement of other department required

Category C - Management help is required

ABC

Categorization

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Stratification

Category No of

Problems

A 5

B 3

C 1

ABC

Categorization

0

5

10

15

A B C

53

1

No.

s of

pro

blem

s

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Major quality defects in Metal Preparation (Bonding)

255

12092 82 78 66 54 45 30

31

46

57

67

76

8491

96 100

0

25

50

75

100

0

200

400

600

800

AV

9000

AV

0640

AV

0650

AV

2141

AV

2151

AV

1540

AV

2500

AV

1340

AV

0290

Cu

mu

lati

ve %

Re

j Qty

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We have selected this problem for QCC

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19

Activity ChartQUALITY CIRCLE NAME DEPARTMENT FACILITATOR MEMBER

PRAYAAS METAL PREPARATION SAMBIT SAHA LEADER: MUNIRAJ

MEMBER: PRADEEP JHAMEMBER: INDERJIT

MEMBER: TARUN KUMARMEMBER: NEHA ARORA

PROJECT REASON FOR SELECTIONExtra Bond on AV 9000 Outer To reduce Rejection Percentage on AV 9000 Outer

MEETING DAY & TIME DATE OF BEGINNING DATE OF COMPLETION

Friday, ( 2 PM to 4 PM) 01-Jul-12 30-Oct-12

Sl. No. Activity WeekA P July' 12 August' 12 September' 12 October' 12

StatusC D 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

1 IDENTIFICATION OF PROBLEM

PLAN

2 SELECTION OF PROBLEM

3 DEFINE THE PROBLEM

4 ANALYSE THE PROBLEM

DO

5 IDENTIFICATION OF CAUSE

6 FINDING OUT THE ROOT CAUSE

7 DATA ANALYSIS

8 DEVELOPING THE SOLUTION

9 FORESEEING PROBLEM OF RESISTANCE

CHECK

10 TRIAL IMPLEMENTATION & CHECK PERFORMANCE

11 REGULAR IMPLEMENTATIONACT

12 FOLLOW UP & REVIEW

PLAN ACTUAL DELAYED

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Define the Problem

Tools: Knowledge Skills Experience

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Bonding Fixture Parts loading in fixturePrimer Application

DryingBond ApplicationDryingUnloading

Process Flow Sequence of Bonding on AV 9000 Outer

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22 October 2, 2008

Extra Bond over AV 9000 outer

Extra

Bond

Extra bonding causes:

1. Extra flash2. Part fitment problem (internal)3. Part fitment problem (customer)

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Analyse the Problem

Tools: Graphs & Charts

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24 October 2, 2008

Observation & Data Collection for Rejection Analysis

Months Total Production Rejection Qty % Rej. Loss in Value

(Rs.) Target % Rej.

January' 12 31542 876 2.78% 33215 0.50%

February' 12 30546 935 3.06% 34547 0.50%

March' 12 35476 852 2.40% 32547 0.50%

April' 12 34587 785 2.27% 32580 0.50%

May' 12 33658 654 1.94% 32340 0.50%

June' 12 32598 849 2.60% 31547 0.50%

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25 October 2, 2008

Rejection Analysis for Extra Bonding on AV 9000 outer

In part no. AV 9000 OUTER rejection was 2.51% from last four months due

to excess bond; leads to customer concerns

The rejection cost is approximate Rs. 32796/- per month.

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Identification of Cause

Tools: Cause & Effect Diagram Brainstorm

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Man

AV 9000 EXTRA BOND

Material

Machine

Method

Unclean Gun

Air PressureWrong Bond Application

Foreign Particles

Bond Viscosity

Wrong Mixing

Improper Fixture Design

Cause & Effect Diagram

Visual aids not clear

Unskilled manpower

No understanding of Pressure gauges

Wrong fixture used

Wooden Fixture Wrong quantity of thinner

Moisture in Airline Stirrer not working

Material Pressure

Needle Problem

Table Problem

Gun Nozzle damaged

Wet part unloading

Improper method of spray

Spray distanceFixture Damage

Variation in loaded quantity

Wrong spray angle

Wrong material loading

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Finding out the Root Cause

Tools: Cause & Effect Diagram Brainstorm

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Gemba on Shop Floor(Validated on 14th Aug’12)Sl. No. Probable Causes Who When Where How Qty. Checked Result Conclusion

1 Wrong Bond Application Pradeep

During Bond application

Bond Booth

DFT test 10 pcs. All pcs found Ok Not a cause

2 Visual aids not clear Tarun Visual Check - Clear & legible Not a cause

3 No understanding of pressure gauges Inderjit Sample question - operators have clear

knoledge Not a cause

4 Unskilled operator Neha Sample Bonding 10 pcs. All pcs found Ok Not a cause

5 Wrong fixture used Pradeep Sample Bonding 10 pcs. All pcs found Ok Not a cause

6 Air Pressure Inderjit Pressure Gauge 10 pcs. Variation in 3 pcs Probable Cause

7 Unclean Gun Tarun DFT test 10 pcs. All pcs found Ok Not a cause

8 Foreign Particles Pradeep Sample Bonding 10 pcs. All pcs found Ok Not a cause

9 Moisture in Airline Muniraj Sample Bonding 10 pcs. All pcs found Ok Not a cause

10 Wooden fixture Muniraj Sample Bonding 10 pcs. Found Variation Probable Cause

11 Stirrer not working Inderjit Sample Bonding 10 pcs. All pcs found Ok Not a cause

12 Needle Problem Tarun Sample Bonding 10 pcs. All pcs found Ok Not a cause

13 Table Problem Neha Sample Bonding 10 pcs. All pcs found Ok Not a cause

14 Materuial Pressure Inderjit Pressure Gauge 10 pcs. Variation in 3 pcs Probable Cause

15 Gun nozzle damaged Neha Sample Bonding 10 pcs. All pcs found Ok Not a cause

16 Bond Viscosity Neha Viscometer once before bonding Found Variation Probable Cause

17 Wrong Mixing Pradeep Sample Bonding 10 pcs. All pcs found Ok Not a cause

18 Wrong quantity of thinner Muniraj Sample Bonding 10 pcs. All pcs found Ok Not a cause

19 Wet part / wrong part loading Neha Sample Check - Not possible to load wrong parts Not a cause

20 Wrong spray angle / distance Tarun Sample Check 10 pcs. All pcs found Ok Not a cause

21 Improper Fixture Design Muniraj - - Found Variation Probable Cause

TRELLEBORG GROUP

Man

AV 9000 EXTRA BOND

Material

Machine

Method

Unclean Gun

Air PressureWrong Bond Application

Foreign Particles

Bond Viscosity

Wrong Mixing


Cause & Effect Diagram

Visual aids not clear

Unskilled manpower

No understanding of Pressure gauges

Wrong fixture used

Wooden Fixture

Wrong quantity of thinner

Moisture in Airline Stirrer not working

Material Pressure

Needle Problem

Table Problem

Gun Nozzle damaged

Wet part unloading

Improper method of spray

Spray distanceFixture Damage

Variation in loaded quantity

Wrong spray angle

Wrong material loading

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31 October 2, 2008

Possible / Suspected Root Causes

Air Pressure

Material Pressure

Bond Viscosity

Wooden Fixture


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Data Analysis

Tools: Why – Why Analysis Brainstorm

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Validation of Suspected Root Causes

1. Rejection Data after change in Bonding Air Pressure

No. of Pcs Air Pressure (kg) OK Pcs Rejected

Pcs Reasons

10 4 9 0

10 4.5 9 1 Colour changed to Yellow

10 5 10 0

10 5.5 10 0

10 6 9 1 Bond entered into the hole

Conclusion: No effect of changing in Air Pressure. This is not a Cause.

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2. Trial Result on Bond Viscosity

Conclusion: No effect of changing in Bond Viscosity. This is not a Cause.

No. of Pcs Viscosity (sec) OK Pcs Rejected Pcs Rejection (%)

50 23 48 2 4%

50 21 50 0 0%

50 19 50 0 0%

50 15 49 1 2%

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3. Trial Result after change in Material Pressure

Conclusion: No effect of changing in Material Pressure. This is not a Cause.

No. of PcsMaterial Pressure (kg/cm2)

OK Pcs Rejected Pcs Rejection (%)

50 1.5 50 0 0%

50 2.0 50 0 0%

50 2.5 50 0 0%

50 2.2 48 2 4%

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4. Trial Result after changing the fixture material to Nylon

Conclusion: Changes in fixture material also gave the same kind (extra bond) of rejection. There’s a tendency of bent in Nylon fixture also, which leads to extra bond on side faces again on longer run.

Side cover has been given & fixture material changed to Nylon

Eliminates extra bond on side faces, but extra bond on collar continues

Extra bond

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5. Unbalancing of plates during movement of material on conveyor and bonding because of improper fixture design

Conclusion:Wrong method have been used for Bonding on AV 9000 outer.

Extra Bond on AV 9000 Outer

Why

Outer surface area wasn’t properly masked

Why

Three was no cover at the sides

Why

Improper Fixture DesignWhy

Wrong Method used

Wrong Method used

Why – Why

Analysis

Why – Why

Analysis

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Developing the Solution & Feasibility Study

Tools: Knowledge Skills Experience Team Spirit

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39

Feasibility Study

We have used wrong method of Bonding. Manual mode has to be avoided.

Trial had been taken on Existing Rotary machine (Full Auto)

There were no extra bonds on outer faces & collar on AV 9000 after trail run

Part has to be fixed into the Fixtures on rotary Machine

OK Parts

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40

Solution Development

Existing Fixtures have key-chuck & it takes extra time for setting change

Parts fixed into the fix diameter fixtures on Rotary Machine

BEFOREHave key-chuck

AFTERFix-chuck

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Foreseeing Problem of Resistance

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42

Foreseeing Problems

SL. No. Root Cause Possible

SolutionsProbable

ResistanceStatus against

ResistanceProposed Solution

1 Improper Fixture Design

Clamp parts into the fixtures on

Rotary

Cycle time / part has been

increased to 11 sec. from 6 sec.

Not agreed by Industrial

Engineering department as cycle time has

been increased

Parts should be clamped such a way that 3 parts can be clamped

vertically

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Trial Implementation & Check Performance

44

Trial Implementation – Proposed Solutions

SL. No.

Possible / Proposed Solution

Trial Implementation Results Conclusion

1 Clamp parts into the fixtures on Rotary

Clamps made such a way that 3 outer can

be fixed in one fixture vertically

The lower most part wasn't properly bonded. But The

upper one & medium part were

uniformly bonded as per specification

Fixtures should be made such a way that 2 outer parts

can be bonded uniformly

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45

Cycle Time Observation during Trial Implementation

Manual Bonding Fixtures with key chuck Fixtures with fixed chuck

Operation Time (sec)



Loading 30 Primer / Bond 11 Primer / Bond 11

Primer 45 Setting change 5

Bond 50

Unloading 25 Total Cycle

Time 150 Total Cycle Time 16 Total Cycle

Time 11

Parts / fixture 25 Parts / fixture 1 Parts / fixture 1

Cycle Time / Cycle Time / part (Outer)part (Outer) 66 Cycle Time / Cycle Time /

part (Outer)part (Outer) 1616 Cycle Time / Cycle Time / part (Outer)part (Outer) 1111

3 parts clamped in one fixture 2 parts clamped in one fixture



Primer / Bond 11 Primer / Bond 11

Total Cycle Time 11 Total Cycle Time 11

Parts / fixture 3 Parts / fixture 2

Cycle Time / Cycle Time / part (Outer)part (Outer) 3.73.7 Cycle Time / Cycle Time /

part (Outer)part (Outer) 5.55.5

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Action Plan – Final Solution

SL. No. Final Solution Target Date Responsibility Status

1

Fixtures should be made such a way that 2 outer parts

can be bonded uniformly

15-Oct-12 Amit Solanki & Nishesh Tripathi Implemented

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47

Effectiveness Check after Implementing Solutions

Rejection% of Extra Bond has dropped down to Zero percentage

Overall Rejection cost on October’12 has been reduced 92.67% than September’ 12

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Regular Implementation

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49

Standardization of ActionSL. No. Description What Where When Who Status

1 Changes in Process Flow Diagram Process PFD 15-Oct-12 IE Done

2Failure Mode analysis

for the modified process step

Failure Mode Analysis PFMEA 15-Oct-12 IE Done

3 Changes in Control Plan Process Sheet Control Plan 15-Oct-12 Quality Done

4

Online Inspection (Viscosity & DFT) in Rotary for AV 9000

outer instead of Bonding booth

Inspection Sheet Rotary 15-Oct-12 Quality Done

5 Detailed modified process One Point Lesson (OPL) Rotary 15-Oct-12 IE, Process Done

6 Work Instruction for the modified process

Standard Operating Procedure (SOP) Rotary 17-Oct-12 IE Done

7 OK & NG Sample to be kept OK & Not-OK Parts Rotary 17-Oct-12 Quality Done

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50

Review of Activity Chart ~ Plan v/s ActualQUALITY CIRCLE NAME DEPARTMENT FACILITATOR MEMBER

PRAYAAS METAL PREPARATION SAMBIT SAHA LEADER: MUNIRAJ

MEMBER: PRADEEP JHAMEMBER: INDERJIT

MEMBER: TARUN KUMARMEMBER: NEHA ARORA

PROJECT REASON FOR SELECTIONExtra Bond on AV 9000 Outer To reduce Rejection Percentage on AV 9000 Outer

MEETING DAY & TIME DATE OF BEGINNING DATE OF COMPLETION

Friday, ( 2 PM to 4 PM) 01-Jul-12 30-Oct-12

Sl. No. Activity WeekA P July' 12 August' 12 September' 12 October' 12

StatusC D 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

1 IDENTIFICATION OF PROBLEM

PLAN

2 SELECTION OF PROBLEM

3 DEFINE THE PROBLEM

4 ANALYSE THE PROBLEM

DO

5 IDENTIFICATION OF CAUSE

6 FINDING OUT THE ROOT CAUSE

7 DATA ANALYSIS

8 DEVELOPING THE SOLUTION

9 FORESEEING PROBLEM OF RESISTANCECHECK

10 TRIAL IMPLEMENTATION & CHECK PERFORMANCE

11 REGULAR IMPLEMENTATIONACT

12 FOLLOW UP & REVIEW

PLAN ACTUAL DELAYED

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Follow Up & Review

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52

Review of Monthly Rejection Trend

Rejection Percentage of Extra bond has been dropped down to Zero (0) percent

Overall Rejection cost on October’12 has been reduced 92.67% than September’ 12

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Review of Rejection Contribution Analysis

12092 82 78 66 54 45 30

21

37

52

66

77

87

95100

0

25

50

75

100

0

200

400

AV

0640

AV

0650

AV

2141

AV

2151

AV

1540

AV

2500

AV

1340

AV

0290

Cu

mu

lati

ve %

Re

j Qty

255

12092 82 78 66 54 45 30

31

46

57

67

76

8491

96 100

0

25

50

75

100

0

200

400

600

800

AV

9000

AV

0640

AV

0650

AV

2141

AV

2151

AV

1540

AV

2500

AV

1340

AV

0290

Cu

mu

lati

ve %

Re

j Qty

Before

After

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54

Benefits : Tangible

1. 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 4364 nos. per shift

3. Cost Saving:

Rejection cost has been reduced to Rs. 1057/- from Rs. 32630/-

4. Customer Concern:

Internal customer is happy

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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.

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56

Horizontal Deployment

The same fixture modification can be done on AV 2141 outer, AV 2151 outer, AV 2091 outer, AV 1340 outer

AV 1340AV 2141

AV 2151AV 2091

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Next QCC Target

Extra Bond in AV 0640B InnerExtra Bond in AV 0640B Inner

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Thought of “Prayaas” Team

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