final seminar d8 method

7/29/2019 Final Seminar d8 method

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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.

3


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4


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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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13


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14


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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).


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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).


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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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% 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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% 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

23


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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 %

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Pareto chart for stub axle(R5-03)


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P t h t f i t k kl


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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
http://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20FMEA.docxhttp://localhost/var/www/apps/conversion/tmp/scratch_6/PROCESS%20FMEA.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).

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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


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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


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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


% 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


% 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%

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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

final seminar d8 method

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