1 | P a g e SUMMER INTERN PROJECT REPORT Submitted By: Kaushal Kumar Submitted to: Mr Karan DograJCB Ltd. Quality department 23/7, Mathura Road Load all unitBallabhgarh, Haryana 2 | P a g e Table of Contents Cover page ...........................................................................................................................................1 Table of contents .................................................................................................................................2 Acknowledgement ...............................................................................................................................3 PIF form ................................................................................................................................................4 About the Organization ......................................................................................................................6 Project Details ......................................................................................................................................7 Introduction to contamination............................................................................................................7 Types of contamination ......................................................................................................................7 Types of rust ........................................................................................................................................8 Effects of contamination ....................................................................................................................9 Cleanliness standard of JCB ............................................................................................................10 Gravimetric Patch test .............................................................................................................................10 Other test apparatus .................................................................................................................................11 Audit and defaulters criteria of JCB ...................................................................................................12 Process mapping of feed pipe manufacturing ....................................................................................13 Fishbone analysis .....................................................................................................................................16 FMEA for pipe processing at IAI .........................................................................................................19 Root cause & why-why analysis ..........................................................................................................23 Possible solution analysis.......................................................................................................................24 Technical Aspects ....................................................................................................................................25 Brief note on IT application...................................................................................................................26 Time management ...................................................................................................................................26 Three problems to solve at IITD ...........................................................................................................27 3 | P a g e Acknowledgement __________________________________________ This project would not have been possible without the support of so many people. First and foremost I would like to express my special thanks of gratitude to my project mentor, Mr Karan Dogra, for the valuable advice, support and guidance provided during the project. I would also like to thank the load all quality department unit- Mr Sanjay Chaudhary, Mr Sanjeev Sharma, Mr Rakesh Gola, Mr Sharma- for the help and guidance provided. I was able to learn a lot of industrial quality practices and about the load all units working by observing and talking with them. I also express my gratitude to Mr Ankur Goyal for his guidance and support during the study of contamination sources in the hose plant of Imperial Auto Industries. I would also like to thank Mr Parveen Yadav for his help and guidance during the visit to the supplier, without which this project would not have been possible. Finally, I would also like to thank JCB for giving me an opportunity to do a project in this prestigious company. 4 | P a g e Information Form: PIFMechanical Engineering Department, IIT Delhi Practical TrainingSummer 2015 FORM A. Personal Information

Complete this form and e-mail as MET410_yourfirstname_yourlastname (or MET420) 1. Student particularsName Kaushal KumarEntry no. 2012ME10681Address

NC-19, Satpura Hostel, IIT Delhi,Hauz Khas,New Delhi, India

Program B.tech.Course Mechanical EngineeringTel (H) Tel (M) 9717514300 E-mail me1120681@iitd.ac.in Tel (other) BlogPIN 1100162. About the organizationName JCB India Ltd. (Ballabgarh)

CEOVipin Sondhi Address

23/7, Mathura Road Ballabgarh, Haryana Tel+91-129-4299000 Tel (M) Tel(other)

FAX +91-129-2309050 BlogPIN 121004 3. Training program (week wise)Start date11/05/2015WeeklyoffSat,SunWorking 9:30am to timings 5:30pm Alternate 5 and 6 working days

Week no.From To Training assignment particulars1 18/05/201522/05/2015Introduction to company, study of the total production line of JCB, understanding the overall flow line 2 25/05/2015 29/05/2015 Study of the load all line, related cleanliness standards of JCB, observing the compliance of SOPs by the workers, sources of contamination on line 3 01/06/2015 05/06/2015 Observing the different tests for contamination and data, study of the working of hydraulics system of JCB, understanding the 7 basic quality tools 4 08/06/2015 12/06/2015 Observing the rust problems in the pipes, study of the different types of rusts and their causes, different measures for prevention of rust, electroplating for rust prevention 5 | P a g e 5 15/06/2015 19/06/2015 Visit to the Imperial auto industries tube plant and plating plant, observing the different processes , sources of contamination, observing opportunities for improvement 6 22/06/2015 26/06/2015 Study of tracker for rust, finding root cause of rust, suggestion for counter measures 7 29/06/2015 03/07/2015Study in the plating plant as well as the pipe plant and validation of the root cause, suggestion of counter measures 806/07/201510/07/2015To find the opportunities for improvement (particularly contamination) in the whole process flow and suggest some improvements 913/07/201517/07/2015 Study the gap in the ram piston, study of the hydraulic systems and hot test 1020/07/201524/07/2015 Implementation at supplier end, solution for the gap problem 4. Executive whom you report toName Karan DograTel (W) DesignationQuality Head Tel (M) 8527240155 Address

23/7, Mathura Road Ballabgarh, HaryanaTel (other) FAX Tel (other) E-mail karan.dogra@jcb.com PIN 121004

Date:Saturday, 20 June 2015 Name (signature) Kaushal Kumar 2012ME10681 6 | P a g e About the Organisation: Businessandmainproducts:JCB manufactures over 300 types of equipment including backhoe diggers, excavators, tractors, skid steers, load all, lift all, Military vehicles and so on. It is the 3rd largest construction equipment manufacturer at the global level. It has over 22 factories around the world -of which 5 are located in India. JCB India offers 25 variants in 7 product lines Backhoe Loaders, Wheeled Loaders, Excavators, and Skid Steer loaders, Telehandlers, Compactors and Pick-and-Carry Cranes. In India, it has its headquarters in Ballabhgarh, Haryana, another two facility in Pune and also another two in Jaipur. The engine used in the JCB machines is also manufactured in the Ballabhgarh facilities itself. This diesel engine is used in-house in various machines like load all and backhoes. However for vehicles with lesser power needs and load demands, like skid steers, a lesser power engine is imported from other suppliers. The Ballabhgarh site is the worlds largest Backhoe manufacturer in the world with a targeted 110 units produced everyday on the line. This plant has also introduced a new unit for Load all machines (the United Kingdom unit is the leading manufacturer in the world of Load all machines). The new line is used as a development for this unit as of now. The current production rate is 2-3 machines manufactured per day. Some innovations made by the JCB over the years in the industry are development of a system to offer multiple services with a single lever and the development of JCB Ecomax engine, which is a very fuel efficient and clean engines in the power range that it operates in (from 56kW to up to 120kW). The level of cleanliness in the plant lines and facilities, and efficiency in the company was truly amazing. 7 | P a g e Project Details: Putting rust to rest PROBLEM: The pipes used in the hydraulic system has a persistent problem of contamination in form of light rust stain in ID of pipes AIM: To find the root cause and eliminate the problem of contamination and rust in the hydraulic feed pipes SCOPE: We can identify probable causes of contamination and rust in the supplied hydraulic pipes from the manufacturing of the pipes by the supplier to their assembly in JCB machines and then take counter measures to eliminate the problem INTRODUCTIONTOCONTAMINATIONINHYDRAULICCIRCUITNeed for Cleanliness:Construction machinery uses a large volumes and different types of fluid in the hydraulic system for power transmission, equipment lubrication, rust prevention and sealing. According to a survey conducted by a pump manufacturer, seventy per cent of the causes of problems in hydraulic equipment were attributable to inadequate maintenance of the quality of the hydraulic fluid.So, maintaining proper levels of cleanliness will help prevent hydraulic machinery problems and greatly improve safety and reliability. It also help in improving the life of the hydraulic fluid. Types of contamination:The contamination can be present in any form- solid, liquid or gas. Solidcontamination-: Sand, fibres, metallic particles, welding scale, sealing materials and wear particles etc.8 | P a g e Liquidcontamination-: Usually water and incompatible oils and greases. Gaseouscontamination-: Air, sulphur dioxide etc. which can create corrosive compounds if dissolved in the fluid. These contaminants can appear during manufacturing, assembly or operation of the machine. TYPES OF RUST: The different types of rust according to chemical formula are- 1.Redrust(Fe2O3.H2O) High moisture content, more amount of contaminant like salts and high oxygen environment. Mostly uniform corrosion is present. 2.Yellowrust(FeO(OH).H2O) Formed on the presence of high moisture content. This type of rust can be easily identified by having a flowing type appearance.3.Brownrust(Fe2O3.H2O) Formed on the presence of high oxygen and low moisture content lead to brown rust. This is mostly responsible for the eating of the metal. 4.Blackrust(Fe3O4.H2O)This forms in absence of sufficient amount of oxygen. It is the most stable form of rust. 9 | P a g e Whiterust(wetstoragestain) This rust is formed on the zinc coating the steel surface. It is formed on zinc coated steel surfaces in presence of moisture and limited presence of oxygen and carbon dioxide. It is white in appearance and very voluminous (100 times the volume of zinc). Wet storage stain can be prevented for a limited amount of time by coating in a light oil, chromate conversion coatings, or phosphate conversion coatings. A more permanent solution is to paint the surface. This is the type of rust that forms in the salt spray testing of the parts when the parts are left in salty test conditions for 96 to 216 hrs. depending on the pre-treatments, coating of the part and thickness of the plating. EFFECTSOFCONTAMINATION:The presence of solid contaminants can lead to jamming of the machinery leading to temporary or sudden failure. The presence of gaseous contaminants like air in the hydraulic oil in contrast to the incompressible oil can lead to performance issues because due to compression of the highly compressible air which leads to sharp fall in the pressure achieved of the hydraulic oil. Once inside the system, hydraulic circuit contaminants greatly affect the performance and life of hydraulic equipment. For example, contaminants in a hydraulic pump develop internal wear to cause internal leakage and hence lower discharges and lower power is generated. Wear particles generated will circulate with the hydraulic fluid to cause further deterioration in the performance of the equipment. Contaminants also enter principal sliding sections of the equipment causing temporary malfunction, scuffing, sticking and leakage and can lead to catastrophic failures. Cleanliness standards of JCB: ISO 4406 is used for the fine particles standards and is generally 17/15/12 for the parts received while for oils and flushing fluids used are 14/16/11 or better. This are also converted for the gravimetric patch test of the parts in absence of a particle counter. The equivalent NAS level used is NAS 6. 10 | P a g e For large particulates, ISO 4405 is used. The solid particles present in the part should not be greater than 1000 microns. For the brake components, the parts used in vacuum-bleed assembly need to be completely free of the liquid contaminants. For other brake parts, the liquid contamination should be less than 400mg with a maximum of 200ppm of water. Further, the liquid contamination should be compatible with the seal material. Gravimetric Patch test in JCB: 1.Flush the required parts, pack them in polybag and dispatch them to the Quality chemical lab. 2.Open the polybag, open one end cap and pour at least 100ml of TCE (tetra chloral ethylene) through this end cap. The solvent is thoroughly shaken and mixed inside the part. 3.Finally, this solvent is poured out in (by part) numbered beakers.4.The 5 microns filter paper is dried in the oven at 82-+- 0.5 degrees Celsius. This is then used with the vacuum suction apparatus to separate the contaminants on the filter paper. The filter paper is again dried at 82+-0.5 degrees Celsius in the oven for pre-specified time. The initial weight of the filter paper is subtracted from the final weight.5.Final weight of filter paper Initial weight of filter paper = Weight of the contaminants 6.The contaminants can be studied under the microscope to check for the large-size particle contamination standard of less than 1000 microns.

Parkers Particle counter: There is a Parkers Particle counting machine which can be used for fine-sized particles standards test in audited parts. 11 | P a g e Other test apparatus: There are other test equipment for testing of other characteristics required for the calibration of the chemical properties e.g. the ph. of any given sample, viscosity of coolant or oil. There is also a salt bath apparatus for checking the electroplating of parts.

Audit criteria of JCB: Part to be auditedAudit criteria Valves (including manifold blocks)/pumps and rams One sample from each supplier facility for one month Pipes Selected pipe assemblies (part numbers identified) every week Hoses Two hoses per week from each hose supplier 12 | P a g e Reservoirs (including diesel tanks) One reservoir for each machine type every 4 weeks Hydraulic oil coolers One cooler for each manufacturer every 4 weeks Defaulters criteria of JCB: Failure to meet large size particle requirements: - The parts meet the fine size but not the large size particulates. The supplier must do a review of the manufacturing procedure and report corrective measures with supporting data. A minimum of 5 samples are tested from the batch and if a minimum of 4 pass both tests, the supply of components is continued but with a rigorous checking. Failure to meet both fine and large size particles: - All stock of the components would be flush-washed by JCB at the expense of the supplier and the component supply shall cease until remedial measures to the satisfaction of JCB are in place. Process Mapping of feed pipe manufacturing (Imperial auto industries) end: Input (C- controlled, NC- non controlled) ProcessOutput(C- controlled, NC- non controlled) Opportunity for contamination C- storage conditions, packaging, pipe length, pipe material, pipe supplier NC- damages during the storage like rust, dents Storage Pipe of required dimensions C- environmental conditions during storage, storage system used e.g. FIFO NC- exact storage period of pipes Environmental conditions during storage Pipe from storage C- Thickness of the pipe, pipe length, cutting tool, feed of pipe, rotating speed of lathe, Pipe O/D turning C- OD at the pipe ends within given tolerances, length of the turning Chips may get lodged in the pipe while heated13 | P a g e coolant to be used, use of compressed air gun to remove the chips inside the pipe, use of mandrels or supportsNC- exact forces applied on the turning surface (CNC m/c) NC- temperature of the pipe surface , temperature of the tool tip, chips formed Turned pipe C- the oil pressure applied to the rollers, the type of rollers used, use of stoppers, the oil used NC- temperature during the rolling, the forces on pipe during rolling Thread rolling C- thread main diameter within given tolerances, thread length NC- Stresses developed in the threads The oil may not be clean or the filter may be past its use. C- Type of m/c used(lathe or cnc), cone angle setup, feed, rpm of work piece,NC- temperature of the tool, forces on the work piece Cone cutting C- cone angle, cone maximum diameter NC- stresses developed in the cone region Chips may get lodged or worse stuck in the pipe, sharp edges/burrs left in the cone may introduce small bits during use and leakage & reduce the system performance C- the drill bit used, the location for the drillings on the pipe, the coolant used, use of fixtures NC- temperature of the drill bit, forces on the work piece Drilling of pipes and reaming of the burred edges C- position of the drilled holes, drill hole size NC- burrs, chips formed Missed or improper reaming of pipe for removal of burrs C- oil pressure applied (backside manual), machine used(cnc 5-axis and 3-axis m/c s), fixtures used NC- exact forming forces applied by the pulleys Pipe Bending (3-axis and 5-axis CNC m/c) C- profile of the pipe within tolerances NC- spring back in pipes, collapsing/dents in pipes,Improper profile/dents, etc. may lead to cavitation and subsequent contamination in the pipes 14 | P a g e C- constant V, gas composition and flow, current, wire speed, wire size, type of welding (only MIG used) NC-defects introduced by hand held machines Stub Welding C- stub welding position NC- weld defects like pinholes, spatter, over-welding, undercut Contaminated (containing oxygen) gas mixture used, improper shielding by gases, rust/contamination present in the files or chisel C- pressure provided, hydraulic oil used, torque wrench limit NC- testing proof pressure(depending on operating pressure of the part) provided by the customer Leakage testing C- result for the testing for weld defects NC- do not check for collapsing or dentingof the pipe Can weaken the weld spot and lead to leakage and other problems over its usage life C- part number, part jig, the chemical composition of the tanks used for electroplating NC- type of electroplating depends on part Plating C- type of electroplating zinc/zinc-nickel, type of passivation, chemicals used, Process parameters like Ph., dc voltage and currents applied NC- uniform thickness of electroplating parameters or chemicals used, improper drying C- type and quantity of flushing oil used, the ISO cleanliness of oil used Flushing NC- the final cleanliness of the part after flushing

Contamination in the flushing oil, presence of large hard particulates in the oil C- the oven temperature, the filter paper size, solvent, minimum quantity of solvent used Millipore testingC- standards for the gravimetric contamination level NC- the value of contamination present Contamination introduced during tests will give false values of contamination in the pipe 15 | P a g e C- the customer for part number, quantity for dispatch NC- date of dispatch Dispatch C- packaging during dispatch NC- quantity for dispatch Improper packaging of the pipes, transport of the pipes Fish bone analysis for contamination in pipes: 16 | P a g e Man: Process parameters not maintained as specified during manufacturing and subsequent processing e.g. ph., dc current applied during Anodic cleaningCapping is not immediate after final flushingMissed quality check by the inspection workersMissed oiling/oil-flushing of a part Non-compliance of the SOPs Machine: Electroplating tanks may have sludge or traces of rust (audit the tanks for traces of iron/rust at regular intervals)Contaminated tools e.g. files used to remove the slag covering on welds(visual inspection of tools for rusting regularly by operator, tool history card) A worn out tool may introduce chips as contaminants or burrs in the pipes inside (usage of compressed air gun & checking of tools life regularly by operator) Failure of the machine to control required parameters or it gives a false reading of the parameter e.g. faulty lathe with wrong RPM may introduce chips into the pipe, no control of ph. of tanks during the electroplating process Filter used in thread rolling, contamination and flushing tests, etc. may not filter correctly because of no regular checks of filter health or filter change after too long time (data for filter from IAI & regular check of the filter contamination level- machine is being implemented, on-line system to check for contamination being implemented) The drier after the electroplating may not completely dry the inside of pipe 17 | P a g e Method: Long term storage of pipes during any stage anywhere from storage to flushing after returning from the electroplating plant (application of FIFO) Inadequate drying of the inside of pipe may lead to rust formation during the time period between transport and further flushing and treatment of the pipe (plugging at ends during electroplating; blow hot air inside the pipes) The spatters produced during the stub welding of pipes introduces contamination in the pipes. It also increases resistance to the flow of the fluid and reduces the power output. There is a time gap between the electroplating of pipe to its transportation & further oil flushing. If this becomes large, the ID of pipe can get rusted from any residual moisture (prevent large time gaps between electroplating and oil flushing by immediate oil flushing of received parts)MIG welding (semi-automatic) produces a less stable arc than automatic TIG welding. This leads to more defects and weaker unstable welds (use of TIG welding for better results) Material: Pipes received at the incoming stage are rusty or have traces of contamination themselves (Contamination report from the supplier for each batch received, auditing at JCB end) The packaging for pipes during their transport does not protect them from the environmental contamination or from physical rubbing and damages (insure proper packaging) The end fittings which are to be assembled with the pipe have rust (Contamination report from the supplier for each batch received, , auditing at JCB end) 18 | P a g e Environment: Storage of pipes at any stage when it is exposed to environmental dust and moisture (closed storage facility) Cleanliness in the work environment is not maintained at the required level (maintaining proper 5s systems for cleanliness) Failure Modes and Effects Analysis for the pipe processing at IAI (pipe supplier to JCB) end: Process step Requirements Mode of failure possible Causes of failureEffects of the failure Current process controls Recommen-ded Action Incoming material Parts should be as per drawing Part material is not as per drawing No inspection for material chemical composition and physical parameters Can lead to failure (collapse, leakage, dent) in the part or incompatibility in the machine Technical reports for the batch from the supplier with each batch, Third party test reports as per the specified testing conditions by IAI -- 19 | P a g e Part dimension is not as per the drawing Faulty standards used or faulty practices by the operator Can lead to collapse, dent, etc. and may cause holdup of the customer line Supplier inspection with each lot 100% important dimensions check of each pipe when operated upon at IAI StorageThe storage conditions should be conducive to protection from contamination and rust The storage conditions are exposed to atmospheric contamination The storage facilities are not constructed well Can lead to contamination and rusting in the pipes Storage is not regulated Proper sealing of storage from atmosphereFIFO is not maintained in the storage of the pipes The pipes are stored in very large batches, the pipes are not stored according to the dates they are received Long storage of pipes may lead to settling of dust, etc. in the pipes, start of rusting in pipes Date of receiving batch notedSmaller batches of pipes according to the customer demand, storage according to the date The storage of pipes is not done properly in the storage bins viz the parts are not properly stacked and covered The pipes are stacked haphazardly in the binsPipes may get scratched, dented, etc. due to rough handling Bins are having stacked pipes Sectioning of the storage bins to prevent stacking of pipes Minimum height from the ground is not maintained Storage racks are of improper model, not taken in consideration Movements in the storage room may lead to settling of dust in the pipes Not implemented Implement a minimum height from ground in the storage racks O/D turning Proper O/D of the turned pipe Pipe O/D is more or less than the desired O/D size M/c setting is improper Threading operation is not proper, leakage in the threaded joints, threaded joints fitment issues Checking of setting by an operator during start of each turning operation, 100% diameter checking with snap gauges during final inspection -- 20 | P a g e Turning process is improper with burr marks on the surface Tool piece is worn out, m/c setting (tool feed, RPM of m/c) is not as per specification Improper threading operation, leakage in threaded joint CNC m/c with provision of program locking, checking for tool regularly, visual inspection Use of History card for checking tool life Thread rolling Threading on required parts as per the standardThread oversize O/D of turned pipe is more, pressure variation in the thread rolling Fitment issues in threaded joints Pressure gauge on thread rolling m/c, check for threads using GO & NO-GO ring gauges for all threads formed -- Thread undersize O/D of turned pipe is less, pressure variation in the thread rollers Leakage in the threaded joints Pressure gauge on thread rolling m/c, check for threads using GO & NO-GO ring gauges for all threads formed -- Thread length more Wrong stopper used, loose stopper Dimensional issue rejection Setup approval for the m/c, issuing of roller for the job Issuing specified stopper with the job card Thread length less Wrong stopper used Leakage in the threaded joint Setup approval for the m/c, issuing of roller for the job, leakage testing for all joints finallyIssuing of specified stopper with the job card Cone cutting To get the required cone size The cone angle is more or less Setting of the m/c, wrong tool piece used Leakage and can lead to reduction in the system performance CNC m/c with program locking, history card for tool life -- Scratch/burr marks on the cone internal surface Setting of the m/c, tool piece worn out, wrong tool piece used Leakage and reduction in the system performance, metal contamination in hydraulic fluid CNC m/c with program locking, history card for tool life -- 21 | P a g e DrillingTo drill holes at the drawing requirements Burr formation at the drilled hole site Drill bit worn out, wrong drill bit used Leakage, seals can be cut 100% flushing, reaming done to remove the burr High flushing coolant with step drill Drilled hole is at a different position than as per the drawing requirements Wrong fixture used, drilling without fixture Fitment issues at the customer end 100% check on Part number on the drilling fixtures, poka yoke in fixtures for correct positioning -- Reaming (de-burring) Removal of the burrs due to drilling Burr is not fully removed Smaller diameter of reaming tool used Can lead to contamination, cutting of seals, etc. Issuing specified reaming tool -- Burr and chips present on the pipe inside Worn out reaming tool is used, blind hole drilling leads to chips, burrs sticking to inner wallsCan lead to contamination, cutting of seals, etc. History card of the reaming tool, one piece cut in each batch to check for burrs and chips Setup fixture for reaming BendingSet up the pipe on the mandrel Mandrel for bending is not placed SOP is not followed Profile of pipe produced is not as specified, pipe may have dents, etc. due to unaccounted forces SOP is written, final inspection with fixture -- Pipe positioned/located incompletely Improper insertion of mandrel in the pipeProfile of pipe produced is improper, defects like dents, collapse, etc. 100% inspection with bending fixture after bending, collet with stopper Fixture with poka yokes for proper positioning of the pipe Excessive bending Pulley is worn out, wrong selection of programme, unskilled operator Fitment problems at customer end, collapsing of pipe History card for the pulleys used, locking of the PLC machines-- Incomplete bending Wrong selection of programme, unskilled operator Fitment problems due to incomplete profile at customer end Locking of the PLC machines -- Wrinkle/Collapse Clearance between pipe ID and Rejection at the customer end or Operator visual inspection Issuing of correct size of mandrel 22 | P a g e mandrel is excessive at the leakage testing point with the job card, check the size with an operator CrackMandrel is not positioned correctly (position less than centre line of pulley) In-house rejection, leakage and rejection at customer end Leakage testing Sufficient precautions in place Stub welding Welding of the stub as shown in the drawing requirements Weld defects like pinhole, spatter, and blowhole Defects introduced by welders carelessness Failure of the welded joint Operator visual inspection Automatization of the welding process The position of welding is not as per the drawing Fixture is not used/correctly, correct fixture is not used Fitment issues at the customer end Part number on the welding fixtures Poka yokes in the fixture for correct positioningLeakage testing The welded assembly should be free of any leakage from poor weld at the time of testing Leakage in whole assembly The fixture for welding is not proper, operator mistake, welding without fixtures Loss of primary function at the customer end Testing in m/c accompanied by visual inspection Leakage in part of the assembly The fixture for welding is not proper, operator mistake, welding without fixtures Loss of primary function at the customer end Testing in m/c accompanied by visual inspection Leakage in the weldingWelding parameters are not maintained, operator incompetency Loss of primary function at the customer end Operator visual inspection and m/c alarm Packaging and dispatch Package the plated pipes and dispatch them for further processing Less or excess quantity of parts supplied Quantity not verified with the bill for the parts required Customer line may stop due to less quantity or cost loss on more quantity supplied Weight the boxfor same type of parts like bolts, operator training 23 | P a g e Wrong parts dispatched to customer Wrong identification of the parts Production line is held up with losses to the customer Verifying of the part number during dispatch -- Root Cause of the problem (Why-Why analysis) 1.The storage in the IAI tube plant led to introduction of contamination and the start of rusting in pipes -> Storage is open to atmospheric dust and moisture -> the storage does not have proper sealing or regulating system to control the exposure to the environment -> Storage of pipes is in open crates and poor packaging -> lack of proper bins andshelves -> Long term storage of pipes ->FIFO is not implemented in storage -> there is no order in the storage of pipes -> no visual documentation about the date of receiving of batch of pipes -> poor administration at the supplier end 2.The processing of pipes in the electroplating plant caused the start of rusting in the ID of the pipes -> The chemical treatment in the tank and subsequent drying and dispatch also interact with ID of pipe -> ID does not get electroplated during this process but is treated to same chemicals which makes ID surface active -> unnecessary exposure to chemical of ID of pipe-> Problem in the drying of the pipe followed by dispatch -> not sufficient time for heater to dry -> inside surface is inaccessible and takes 24 | P a g e more time to dry than outer surface -> unnecessary exposure to chemical of ID of pipe Possible solutions to the problem 1.Electroplating the inside surface of the pipes:This can be achieved by any of the following- a.Auxiliary anode inside the pipe. However this method only works for straight pipes, not for any bent pipe. If we electroplate the straight pipe and then bend it, the outer electroplating will peel from the bending & interaction with the bending pulleys. The inside surface electroplating will flake and cause problem of contamination in the pipe. b.Hot dip zinc plating. The surface of the plating will be very rough and cause lower performance of the machine. In the future, it will lead to contamination by flaking off from the inside surface. It weakens the high strength steel by hydrogen embrittlement. c.Brush electroplating. A brush to electroplate the inside of pipe may be designed. However it will have tendency to be thicker at one end and thin at the other. It requires a lot of operator involvement. So it is not desirable to switch to brush electroplating from tank electroplating because tank electroplating requires almost no operator supervision. So this approach does not have any workable solutions in sight. 2.Insulating the pipe inside from the electrolytes in the electroplating tanks using plugs:Because the ID of pipe is not being electroplated, the ends of the pipe can be plugged during the electroplating process of the pipe to prevent the electrolytes from coming into contact with the inside of the pipe. After the drying of the pipes outside surface, the plugs can be removed and reused. 3.Prevent long term storage of pipes:25 | P a g e For this, the incoming date of the pipes should be recorded with the batch of pipes. A maximum number of pipes should be set for the different types of pipes in the storage. Pipes with less demand or pipes which are stored for more than one month should be stored with sufficient protection. Technical Aspects: Data security: The Lotus email software on the company PCs does not let employees to send the emails to any mail other than the certified dealers or between themselves. The USB port in the company laptop and desktops also does not allow the mounting of the pen drives or external hard drives. This insures the safety of the company data. However, it also causes some trouble to the employees when they are working from home or are on some company visit to an out of station supplier or place. Standard operating procedure: The SOPs helped even a newcomer to understand the proper procedure to follow. This helps to insure a proper standardised working method by workers. These were at each of the station on a board available to the workers. On- line testing: The oils and coolants from the finished machines are sent to the lab for analysis at regular intervals, even once in two hours. This insures that any contamination in a batch of oil received or in a machine is found out if it had escaped previously or had been contaminated in the meanwhile. Packaging standards: The packaging in JCB for different parts is very strictly followed. Workers do not open the caps of pipes just before the lunch break. Any contamination while transportation is minimised with proper packaging. The protocols are very strict since even a little atmospheric contamination can lead to failure of the machine. Safety aspects: The JCB entrance reception does not allow anyone not wearing shoes to enter the premises for safety purposes. The first day we were unable to 26 | P a g e visit the factory lines because we were not wearing the standard safety shoes. Also everyone on the line is provided with goggles to prevent accidental injury to the eyes. Brief note on IT application: The employees working in the office have either a company provided desktop or a company provided laptop. The desktops and the laptops have their USB disabled for pen drives as a safety feature to prevent the company data from being taken out for mal purposes. Each office has a printer which is used by employees to print hard copies. Siemens PLM software is used to maintain the database. Every computer has a Siemens Teamcenter software installed for the purpose of accessing it with login. Lotus email software is used to manage the email of the employees. This insures the exchange of information between the employees and the dealers. Much of the work is done on excel and windows is installed in the laptops. The sites like google drive, gmail are blocked for the security purposes of the data. There was wifi installed in the office premises but it required employee login. These security measures indicate the importance of the IT department which is used for most of the office works. Time management: The time spent by a junior/senior engineer and a manager differ. In the quality lab, I worked with a senior engineer and also observed his manager, Mr. Tarun, who often spent his time in meetings with other employees and recently went on the UK plant of the JCB to study and find out ways to better the Ballabhgarh plant. The engineers mostly spent time in the quality checks, meetings with the part suppliers, excel work to present to the managers. The work was often repetitive like daily check for contamination or maintaining smooth functioning of the production line and solve the problems encountered. The work done by 27 | P a g e them was presented to the managers. A roughly approximate breakup of the time spent by the junior/senior engineer and a manager are as given below: Junior/senior engineerTechnical work Analytical work Computer workPeople management Discussion and meetings OtherManagerTechnical work Computer work People management Discussion and meetings Other28 | P a g e Three Problems worth of solving at IITD:- a) Synchronisation of the hydraulic pistons in the boom-dipper section: The pistons in the boom section are very important and face large amounts of stresses. Due to some unseen failure, even a slight difference in the movements of the two pistons located symmetrically about the boom can cause a mechanical failure or breakage of the machine. A new design element can be introduced to reduce the accidental happening of such accidents. b)Failure of hoses:The hoses often fail due to wear resulting from rubbing with the other parts of the machine, getting hit by stones during movement. Proper protection for the pipes and their positioning in the machine with respect to the pipe needs to be designed. c)Gap remaining in the ram pistons: The ram and boom pistons move simultaneously in some synchronisation. If one of the pistons closes without closing of the other piston i.e. some gap remains in one of the pistons. Over the usage of the machine, this gap would become more strained. When the stress exceeds the tensile strength of the ram mechanism, it can lead to the breakage of the mechanism. This is a serious manufacturing issue. -------------------------------------------------------------------