final seminar d8 method
TRANSCRIPT
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Presented by:
NITHIN J
USN: 4JC11MMT09
Under the Guidance of:
Dr M S PRABHUSWAMY
Professor
Dept of mechanical Engg,SJCE,Mysore
STUDY AND ANALYSIS OF PROCESS
CAPABILITY OF 4000 TON MECHANICAL
PRESS USING 8D METHOD
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This project aims towards improvement of both product and process
by eliminating recurring problems of 4000 ton mechanical press byusing 8D method.
Forging is a mass production activity. Some of the manufacturing
equipments like Mechanical press produce a large number of partsin its running time.
Break down of these machines lead to unavailability of these
machines there by affecting the process performance in terms of
major production loss and also effects quality of the product.
To achieve the objective an important problem solving method
Eight disciplines of problem solving method can be used.2
INTRODUCTION
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8D PROBLEM SOLVING METHOD
The 8D Problem Solving (Eight Disciplines) approachcan be used to identify, correct and eliminate therecurrence of quality problems.
8D is a problem-solving methodology for product andprocess improvement. It is structured into eightdisciplines, emphasizing team synergy.
The team as a whole is believed to be better and smarterthan the quality sum of the individuals.
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STATEMENT OF PROBLEM
Frequent break downs of 4000 ton mechanical presseffects both process and product quality.
Therefore there is a need to undertake a permanentcorrective action plan to reduce the frequent break
downs of this machine .
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OBJECTIVES
To carry out Break down analysis of machines.
To prevent root causes and its recurrence.
To establish a permanent corrective action based onstatistical analysis of the problem.
To improve process and product quality.Using 8D problem solving method
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SCOPE OF THE STUDY
Eight disciplines(8D) of problem solving method has matured into
one of the most powerful method used to approach and to resolveproblems in industries.
8D method is adopted to identify, correct and eliminate recurring
problems and it is useful in product and process improvement.
8D method focuses on the origin of the problem by determining itsroot causes. Analysis is made to find the causes of the failures andthereby preventing similar break downs.
Some of the break downs can be reduced by implementing newideas through RCM tools like WHY-WHY analysis, fish bonediagram, IS/IS NOT work sheet, Pareto chart etc., 7
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METHODOLOGY
Literature review about eight disciplines of problem solvingmethod.
Preliminary study about production process.
Setting the objectives for the study
Data collection about machine history.
Selection of appropriate tools and techniques for the study. Implementation of team based problem solving method.
Finding the root causes for the break downs.
Fishbone diagram
Why-Why analysis Development of counter measures.
Implementation of counter measures.
Check the results.8
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ORIGIN OF THE EIGHT DISCIPLINES CONCEPT
Problem solving is a process, an activity whereby a best value is
determined for an unknown, subjected to a specific set of conditions.
It is a means by which an individual uses previously acquired
knowledge, skills and understanding to satisfy the demands of an
unfamiliar situation.
The 8D process evolved from Dr. Demings Plan-Do-Check-Act
(PDCA) cycle, and the Kepner Tregoe Problem Solving Decision
Making (PSDM) process.
The U.S. Government first used an 8D-like process during the Second
World War, referring to it as Military Standard 1520 (Corrective action
and disposition system for nonconforming material).9
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It was introduced in 1974 and used by the military suppliers until 1995.
The main goal was to indentify errors, make root cause analysis,limitation of waste, prevent reoccurrence, cost reduction and raise the
quality
Ford Motor Company first documented the 8D method in 1987 in acourse manual entitled "Team Oriented Problem Solving".
Ford later introduced their 8D framework to Motorola in 1989, andrequired that Motorola used it to resolve all problems involving Ford
products
8D methodology has been propagated by Ford on automotive industry
and is well known to many companies in the electronics industry.
The 8D framework was later adopted by especially the automotiveindustry in order to solve problems
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4000-TON FORGING PRESS(MECHANICAL PRESS)
11Schematic diagram showing the working of
forging press
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PIE CHART FOR NUMBER OF DEFECTS OF 1109 STUB
AXLE(R5-03)
195
144
12
45
77
U/F
PIT MARK
DAMAGE
S/C
FOLD
QUENCHCRACK
LAP
BLOCKER
1
15
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PIE CHART FOR NUMBER OF DEFECTS OF SUMO
VICTA KNUCKLE RH(R5-04)
421
339
48
20
76
96
U/F
PIT MARK
DENT
DAMAGE
S/C
U/S
QUENCH
CRACKLAP
BLOCKER
16
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PIE CHART FOR NUMBER OF DEFECTS OF SUMO
VICTA KNUCKLE LH(R5-05)
218
2
75
16
53
88
6
14 U/F
PIT MARK
S/C
FOLD
U/S
QUENCH
CRACKLAP
O/H
17
PROCESS CAPABILITY FOR STUB AXLE(R5 03)
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PROCESS CAPABILITY FOR STUB AXLE(R5-03)
The allowable thickness dimension for the product is 14+2.5mm for upper
specification limit (USL) and 14-0.5mm for lower specification limit (LSL).
PROCESS CAPABILITY OF R5-03.docx
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http://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-03.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-03.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-03.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-03.docx -
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PROCESS CAPABILITY FOR SUMO VICTA KNUCKLE
RH(R5-04)
The allowable thickness dimension for the product is 27+2.5 mm for upper
specification limit (USL) and 27-0.5 mm for lower specification limit (LSL).
PROCESS CAPABILITY OF R5-04.docx
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PROCESS CAPABILITY FOR SUMO VICTA KNUCKLE
LH(R5-05)
The allowable thickness dimension for the product is 27+2.5 mm for upper
specification limit (USL) and 27-0.5 mm for lower specification limit (LSL).
PROCESS CAPABILITY OF R5-05.docx
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Percentage rejection chart of R5-03 due to U/F
Jun'12 July'12 Aug'12 Sept'12 oct'12 Nov12
% Rejection 1.6 5 8.4 6.5 2.8 3
TARGET 2 2 2 2 2 2
0
2
4
6
8
10
12
%R
ejection
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Percentage rejection chart of R5-04 due to U/F
Jun'12 July'12 Aug'12 Sept'12 oct'12 Nov12
% Rejection 6.7 2.9 2.9 4.7 2.5 1.5
TARGET 2 2 2 2 2 2
0
2
4
6
8
10
12
%R
ejection
22
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Percentage rejection chart of R5-05 due to U/F
Jun'12 July'12 Aug'12 Sept'12 oct'12 Nov12
% Rejection 2 2.4 2.8 7.2 0.82 1.1
TARGET 2 2 2 2 2 2
0
2
4
6
8
10
12
%R
ejection
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D2- PROBLEM STATEMENT
The major frequent problems identified in 4000 ton forging
press are:
Ram slip problem
Forging Press stroke problem
Improper working of top ejection cylinder
Due to these problems of the machine, the product as well
as the process is directly affected.25
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D3- DEVELOP THE INTERIM CONTAINMENTACTION(ICA)
The ICA for the Ram slip in the forging press may be: Ramassembly locking bolts to be tightened with the torque wrenchto prevent the problem from spreading.
The ICA for the Forging Press stroke problem may be:Proximity sensor to be checked, sensing limit to be adjusted.
The ICA for theTop ejection cylinder problem
may be:Clamping fasteners and seals of ejection cylinder to bechecked ,change if necessary.
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D4 - DEFINE AND VERIFY ROOT CAUSE
Root Cause Analysis is a method that is used to address a problem, in
order to get to the rootcause of the problem.
It is used so that we can correct or eliminate the cause, and prevent theproblem from reoccurring.
A Root Cause Analysis will disclose:
Why the incident, failure or breakdown occurred
How future failures can be eliminated by:
changes to procedureschanges to operation
training of staff
design modifications 27
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ROOT CAUSE ANALYSIS - PROCESS
Step 1 problem identification
Step 2 Define Problem or Issue
Step 3 Conduct Data Analysis
Step 4 Determine Root Cause(s)
Step 5 Improvement Planning
Step 6 Evaluate Progress28
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1. Ram slip problem
Cause Analysis: Fish bone diagram
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Why Ram slip in the machine
Why Over load on die
Why Stroke length vary
Why
Improper torque setting on adjustment
unit
Why Worn out of aluminium liners
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5 Whys:Problem: RAM SLIP IN FORGING PRESS
D5 P t ti ti (PCA)
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D5- Permanent corrective actions(PCA)
Permanent corrective actions:
Check the over loading condition on the die.
Aluminium liners spares must be maintained.
Check the condition of the ram adjustment unit, modify if necessary.
Aluminium alloys can be used instead of aluminium.
Torque must be set properly on the adjustment unit.
Periodic alignment of the ram unit to be done once in a week or oncein 15 days.
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D6- Incorporation in the system
PM strengthened: Time based maintenance
Point added in PM: Alignment of the ram unit to be checked
in weekly Preventive maintenance schedule instead of monthly
Preventive maintenance schedule.
Torque on adjustment unit should be min 55 N-m.
One point lesson: Check for over load on the die every day during the start of the
first shift by the operator.
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2. FORGINGPRESSSTROKEPROBLEM
CAUSE ANALYSIS: FISHBONEDIAGRAM
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Why Cam setting changed
Why Cam plate sheared
Why Due to high vibration
Why
Machine foundation bolts loose
Why Improper maintenance
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5 Whys:
Problem: Press stroke problem
P t ti ti
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Permanent corrective actions
Before starting, check the condition of the machine.
Cam unit spare to be maintained.
Use of good quality foundation bolts, replace if necessary. Fly wheel bearing condition to be checked regularly.
Check and modify the guide clearance.
Flush the grease line regularly.
Incorporation in the system
PM strengthened:
Point to be added in PM: During monthly PM check the machine
foundation bolts condition. This increases their life considerably.
Check for the guide clearance (0.4-0.5 mm) in the quarterly PMschedule. 35
3 IMPROPER WORKING OF TOP EJECTION CYLINDER
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3. IMPROPERWORKINGOFTOPEJECTIONCYLINDER
CAUSE ANALYSIS: FISHBONEDIAGRAM
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Why Ejection pin not working
Why
Fulcrum lever not working
Why Rack damaged on ejection unit
Why
i. High air pressure in the ejection cylinder
ii. Due to burr entry
Why
i. Pressure regulator valve not installed
ii. Poor lubrication 37
5 Whys:
Problem: Improper working of top ejection cylinder
P t ti ti
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Permanent corrective actions:
Pressure regulator valve to be installed on the inlet air line.
Proper greasing to be done to fulcrum lever and rack and pinion unit.
Pressure level in the air line to be set properly, if necessary replace FRL unit.
Addition lubrication point to be provided at the of the ejection unit.
Incorporation in the system
PM strengthened:
Point to be added in PM:During daily PM check the pressure level (5.5-7 bar) inthe air line.
Time based maintenance:
Remove the fulcrum lever and Rack and pinion unit every month, clean it properly,
regrease it and again fix it back.
Check for proper working of pressure regulator valve on the inlet air line.
One point lesson:
Additional lubrication point to be provided at the point of ejection cylinder unit.
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PARETO ANALYSIS
Pareto analysis is a statistical technique in decision making that
is used for selection of a limited number of tasks that produce
significant overall effect.
It uses Pareto principle- large majority of problems (80%) are
produced by a few key causes (20%).
This technique helps to identify the top portion of causes that
need to be addressed to resolve the majority of problems.
It is common to refer to pareto as "20/80", under the assumption
that, in all situations, 20% of causes determine 80% of problems.39
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56
78
9195
98.4 99.54 100
0
20
40
60
80
100
120
0
50
100
150
200
250
U/F BLOCKER LAP DAMAGE QUENCHCRACK
FOLD PIT MARK
Numbers
Defects
NUMBERS
cum %
40
Pareto chart for stub axle(R5-03)
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P t h t f i t k kl
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46
64.6
80.4
91.694.9 97.8
99 99.4 100
0
20
40
60
80
100
120
0
50
100
150
200
250
Numbers
Defects
NUMBERS
CUM %
42
Pareto chart for sumo victa knuckle
LH(R5-05)
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FAILURE MODE AND EFFECTS ANALYSIS
FMEA (Failure Mode and Effects Analysis) is a systematic
method of identifying and preventing system, product and
process problems before they occur.
FMEA is focused on preventing problems, enhancingsafety, and increasing customer satisfaction.
FMEAs are conducted in the product design or process
development stages, although conducting an FMEA onexisting machinery, products or processes may also yield
benefits.43
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BENEFITS OF FMEA
Contributes to improved designs for products and processes.
Higher reliability
Better quality
Increased safety
Enhanced customer satisfaction
Contributes to cost savings.
Decreases development time and re-design costs
Decreases waste, non-value added operations
Contributes to continuous improvement.44
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PROCESS FMEA
Process Failure Mode and Effects Analysis (PFMEA) is often
developed at the time when a new product or process is being
introduced.
This activity is very beneficial when ordering tooling and
equipment as well as determining process controls.
PFMEA is a collection of possible causes and mechanisms for
failure modes, as determined by a team.
It can also play an important role in day to day improvement and
problem solving. 45
PROCESS FMEA.docx
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D7- PREVENT RECURRENCE
In this step the team analyses whether the corrective
action implemented would prevent or improve the qualityof similar products and processes.
The changes in the procedures and operations must be
communicated to every one.
D8- RECOGNISE THE TEAM
All the efforts made by the team should be recognised and
informed to the top level management of the organisation.
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AMW MGM forgings Pvt Ltd
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AMW MGM forgings Pvt. Ltd.,
Preventive maintenance check list of 4000 ton forging press
Sl. No. Activity description Freq Specification Date Observations/remarks
1 Check back lash in press Y Between 1-2 mm 8-02-122 Check seal condition of clutch &
brake Q Checked ok 15-04-123 Check seal condition of counter
balance cylinder Q No damage 18-04-12
4 Check piston & piston rodcondition Q No damage 18-08-12
Added based on
history card
review
5 Check main motor couplingalignment & condition Q Alignment done 22-08-12
6 Check any damages / leakagesfrom lubrication line Q No leakage 28-08-12
7 Lubricate bull gear & lay shaftbearings H No sound should come 14-06-12
8 Check conditions at pressure &friction plates of clutch H No worn out 14-06-12
9 Check conditions of brakepressure & friction plates H No worn out 23-06-12
10 Check seal condition of counterbalance cylinder H No damage 18-12-12
11 Clean & service lubrication pump H Operate smoothly 18-12-12
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P i t dd d ft t l i
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Points added after root cause analysis
Sl. No. Activity description Freq Specification DateObservations/
remarks
1Check for the alignment of the
ram unitW Checked ok 27-03-13
2 Check for over load on the die W No over load 27-03-13
3Check torque on the ram
adjustment unitW
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Process capability for 1109 Stub axle(R5-03) after implementation
of 8D methodThe allowable thickness dimension for the product is, 14+2.5mm for the upper
specification limit (USL) and 14-0.5mm for the lower specification limit will (LSL).
49
PROCESS CAPABILITY OF R5-03 AFTER IMPLEMENTATION OF 8D
METHOD.docx
Process capability for Sumo victa knuckle RH(R5 04) after
http://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-03%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-03%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-03%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-03%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-03%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-03%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docx -
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Process capability for Sumo victa knuckle RH(R5-04) after
implementation of 8D methodThe allowable thickness dimension for the product is 27+2.5mm for the upper
specification limit (USL) and 27-0.5 mm for the lower specification limit (LSL).
50
PROCESS CAPABILITY OF R5-04 AFTER IMPLEMENTATION OF 8DMETHOD.docx
Process capability for Sumo victa knuckle LH(R5 05) after
http://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-04%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-04%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-04%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-04%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-04%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-04%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docx -
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Process capability for Sumo victa knuckle LH(R5-05) after
implementation of 8D methodThe allowable thickness dimension for the product is 27+2.5mm for the upper
specification limit (USL) and 27-0.5 mm for the lower specification limit (LSL).
51
PROCESS CAPABILITY OF R5-05 AFTER IMPLEMENTATION OF 8DMETHOD.docx
P t j ti f 1109 St b l (R5 03) d t U/F
http://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-05%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-05%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-05%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-05%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-05%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20CAPABILITY%20OF%20R5-05%20AFTER%20IMPLEMENTATION%20OF%208D%20METHOD.docx -
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Percentage rejection of 1109 Stub axle(R5-03) due to U/F
after implementation of 8D method
Jun'12 July'12 Aug'12 Sept'12 oct'12 Nov12 Mar'13 Apr'13 May'13
% Rejection due to U/F 1.6 5 8.4 6.5 2.8 3 2 2 2.1
TARGET 2 2 2 2 2 2 2 2 2
0
2
4
6
8
10
12
%R
ejection
Target 2%
52
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Percentage rejection of Sumo victa knuckle RH (R5-04) due to
U/F after implementation of 8D method
Jun'12 July'12 Aug'12 Sept'12 oct'12 Nov12 Mar'13 Apr'13 May'13
% Rejection due to U/F 6.7 2.9 2.9 4.7 2.5 1.5 2 1.71 2.08
TARGET 2 2 2 2 2 2 2 2 2
0
2
4
6
8
10
12
%Rejectio
n
Target 2%
53
P j i f S i k kl LH (R5 05) d
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Percentage rejection of Sumo victa knuckle LH (R5-05) due to
U/F after implementation of 8D method
Jun'12 July'12 Aug'12 Sept'12 oct'12 Nov12 Mar'13 Apr'13 May'13
% Rejection due to U/F 2 2.4 2.8 7.2 0.82 1.1 1.87 2 2.1
TARGET 2 2 2 2 2 2 2 2 2
0
2
4
6
8
10
12
%Rejection
Target 2%
54
CONCLUSION
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CONCLUSION
After the analysis it is found that the process is improved and
the rejection rate of the component due to Under filling isreduced by using 8D method.
Some of the tools of root cause analysis like 5-why analysis,fish bone diagram, pareto analysis are implemented to identify
the actual causes of the breakdown.
Then some necessary actions was taken to improve the systemusing root cause analysis and counter measures weredeveloped such that similar type of break downs can be
reduced.
After the implementation of the 8D method there is a significantincrease in the values of CP and CPK . 55
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ProductCP CPK
BEFORE AFTER BEFORE AFTER
1109 Stubaxle(R5-03)
0.705 2.115 0.624 1.957
Sumo victa
knuckle
RH(R5-05)
0.901 2.771 0.818 2.736
Sumo victa
knuckle LH
(R5-05)
0.584 1.976 0.538 1.963
Also after the implementation of the 8D method the rejection rate
considerably meets the target value of 2% and ranges from 1.71% to2.1% between period Mar-13 to May-13.
Hence the process and the product can be improved significantly
using 8D problem solving method.56
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THANK YOU