qc project - copy (2)

8/15/2019 Qc Project - Copy (2)

1/40

QC CIRCLE PRESENTATION

BY

CHENNAI TIGERSRNAIPLBODY LINE #

1


2/40

QC CIRCLE TEAM – BODYSHOP

RAMUKUMAR PKARUPAN MUTH

U

SUDEESH

VASU

RAJAGOPAL

2

Facili a !"L a$ r

S%& L a$ "

KARTHIK T a' ' '& " T a' ' '& "

T a' ' '& "T a' ' '& "


3/40

OBJECTIVE: To Improve SUBFLOOR Straight thru ratio(STR

@

TCF BY RE R BS COVER STU! F ILURE ELI"I# TIO#

BODY SHOP( SUB


4/40

QC CIRCLE THEME

)S*!+ ,

B!$- # 1

)QC Ci"cl T* ' ,

ELIMINATION OF REAR ABS

COVER M. STUD FAILURE IN

H/0 MODEL

)QC Ci"cl Na' ,

CHENNAI TIGERS

To Improve Bo$% Shop Straight thru ratio @

TCF


5/40

QC THEME SELECTION BASED SUBFLOOR AOP KPIFSTR TARGET A+"il213 4 MARCH 1. 5 6c

SUBFLOOR AOP CONTROL ITEMONTIORING SHEET

17F STR AT TCF TARGET NOT ACHIEVEDTO APRIL 13 DELIVERY KPI6

87 V1 QUALITY DEFECT OUTFLO9 QUALITY

T&E"E SELECTIO# :

AOP KPI’S are unachieved:

DELIVERY(STR), QUALITY


6/40

SU !LOOR "O#E STR AT T$! !Y%&

T&E"E SELECTIO# RE SO# :

'

%'

('

)'

*'

&'

+'

,'

-'

.'

%''

.*.- .,

%'' %'' %''

SU !LOOR STR TRE#D !OR /,. R0#STR

17 F STR TARGET NOACHIEVEMEN

H/0 DELIVERY87 HIGH REPAIR TIM

COST6:7 EFFECT ON

CUSTOMER QU Y6

TARGET ;1


7/40

ACTIVITY SCHEDULE


8/40

0

20

40

60

80

100

34

1814 13

5

38.6

59.1

75.0

89.8

95.5

H/0R>N STR STUD FAILUR OFFLINE TREND AT TCF FOR . MONTHS

Axno of cocern

REAR ABS COVER STUDFAILURE IN H/0 MODEL

CURRENT STATUS( DATA COLLECTION AND ANALYSIS


9/40

"EC#14 $A%#15 &E'#15 MAR 15 A(RIL#15 MA)#15 $*%E 150

1

2

3

4

5

6

7

89

7

8

5

6

7

STR Ou34567 8A S $OVER STUD !AILURE (/ .)

96n3h

#O O! $ARS

QC STORY ; CURRENT STATUS GRASPING

MONTH 9ISE STR OFFLINE TREND DATA

FOR ABS COVER STUD FAILURE


10/40

QC CIRCLE THEME

)S*!+ ,

B!$- # 1

)QC Ci"cl T* ' ,

ELIMINATION OF REAR ABS

COVER M. STUD FAILURE IN

H/0 MODEL

)QC Ci"cl Na' ,

CHENNAI TIGERS


11/40

pr-.#15 MA)#15 $*%E 15# $*L) 15#

0

2

4

6

8

7

0

OFFLINE STR IN TCF

96n3h

DPU

QC STORY ; TARGET SETTINGCHALLENGE 1


12/40

PICTORIAL DETAILS OF REAR ABSCOVER STUD LOCATION

REAR ABS COVER STUD POSITION

REAR A', C/+ER &I I%(/I%T

C!?c "?@* " all

c%@ !' "$i@@a i@ $

clai' !"" +ai"

+E, e n-t-on of o

+1 +2"e n t-on $ !e ent !r e

r e e n t-on

M!@ !c%@ !' "@+!i? !% i?

% @ i!??ai" i? @%" -

17REAR ABS COVER FI ING STUDAFFECTS CUSTOMER SAFETY


13/40

BRAIN STORMING SESSION


14/40

BRAIN STORMING

7 F !" A? l @i@


15/40

MA% MACHI%E METH/"

MATERIAL,/THER,

Stud welding angle notmaintained

New operatordoingthe process

Stud Gabari panel gap and Bush loosening

Manual clamp imprope

uring the rework oGabari not used

Supplier part matching"hickness high#!latnessuneven in RR MBR$%&'R ASS( CR%SS

"rim Matching part not alig

Stud Gun Angularit)setting concern

*igh thickness o! sheet metal+,mm-

Stud Gunparameter

1 / . REAR A S $OVER 9+ STUD ELD!AILURE

%il Contamination-

Stud strengthcon!irmation notdone

$ow AwarenessStud weld.rocessparameter ande/uipmentconcerns

*igh speedstud gunhandling

&eldc)cle notcomplete

Clamping shaking and B

Stud colletcarbon deposit

.7 Fac !" A?al-@i@ –


16/40

S5 #6 *9 9ain !ac36r; P6in3; 46r veri4

% 9A# SKILL LEVEL STUD ELD 1U# /A#

9A# K#O LED1E STUD ELD I#TE1RITA A

9A$/I#E STUD ELD EQUIP9E#T PARA9ETER PARA9ETEA#1ULARITY,!EE

* 9A$/I#E $OLLET,!LAS/ S/EILD ,EART/I#1 !ORSTUD ELD EQUIP9E#T

$OLLET LI!E, !LEART/I#1 LO

& 9ET/ODS RI1ID SEATI#1, 1APS, !LAT#ESS I# PA#ELPRO!ILE

RI1ID SEATI#1, 1APS/EILD

+ 9ET/ODS STUD 1A ARI STUD 1A ARI DESI1A$$ESS LI

9ATERIAL OIL $O#TA9I#ATIO#, T/I$K#ESS, PRO!ILE!LAT#ESS,

OIL $O#TA9I#A1RADE(SP$, 1

' F CTOR # LYSIS * " I# F CTOR # LYSIS


17/40

MA% 9HY 9HY 9HY 9HY VERIFICATION

RESULT

1. ,T*" EL"C)CLE %/TC/M(LETE

*% A% LE%/TMAI%TAI%

/(ERAT/R %/TA ARE /&(ER(E%"IC*LARI

T)

,T*" *%*,A E I%A% *LARTI), ITCH"EACTI+ATE"M/"E

/8 A, (ER,TA%"AR"


"E&ECTI+E"R/( "/ %

TIME

,T*" *%R/*TI%IM(R/(ER

,T*" *% H/,ER/*TI% %/T(R/(ER -t:,pr-n! ' ncer

;,T*" *%EL/% ATI/%/% /((/,ITE"-rect-on

/8 A, (ER,TA%"AR"


LI&TI% /&*% 'E&/RE

(R/CE,,C/M(LETI/%

LAC8 /&A ARE%E,, /%,T*" EL"I%T ERIT)

HI H ,(EE",T*" *%HA%"LI%

% ; RE,*LT&/*%" %

H) H); A%AL),I,


18/40

%< 9A# SKILL LEVEL: STUD ELD 1U# /A#DLI#1 0

Ke= 4ac36r: /i>h ;?eed 7e5d 1un hand5in>5ead; 36 7e5d c=c5e inc6@?5e3e

Signi!icant Not si

' ' F CTOR VERIFIC TIO# :

H) H) A%AL) I


19/40

MACHI%E 9HY 9HY 9HY 9HY VERIFICATION

RESULT

17 STUD GUNCOLLET ANDFLASHSHEILD9ORN OUT

HIGHCARBONSPATTERDEPOSITON THECOLLETAND FLASHSHEILD

COLLET>FLASHSHEILDCLEAING DONE8 TIMES PERSHIFT

NG( STUDFAILUREOBSERVED

87 STUD

9ELD GU NPARAMETER

STUD 9ELD

GUNCURRENTPARAMETERVARIATION

DROP OF

CURRENTDURING STUD9ELD PROCESS

OK AS PER

STANDARD

:7 STUD GUN0< DEGREEANGULARITYSETTING ISSUE

STUD 9ELDGUN

ANGULARIT YBYPASSED

FEED BACKSIGNAL NOTPROPERRESULTING INERROR GREENLIGHT NOT

GLO9

STUD GUNBASE PANELPROFILEUNEVEN INFLAT NESS

PROFILEFLATNESSVARIATION

NG( FLATNESS FOUNUNEVEN

EARTHING ;

H) H); A%AL),I,


20/40

< 9achine: S3ud ELD 1U# .' De>ree An>u5ari3=

F CTOR VERIFIC TIO# :

Signi!icant Not

sign

%


21/40

METH/" 9HY 9HY 9HY 9HY VERIFICATION

RESULT

17 STUDGABARI TOBASE PANELGAP

HIGHTHICKNESSOF STUDGABARI

STUD GABARIFRP MATERIALTHICKNESSHIGH

CURVEPROFILEGABARI NOTSEAT 9ITHPANEL(HIGHGAP

OK AS PERSOP

87STUD

GABARI TOBASE PANELGAP

MANUAL

CLAMPSIMPROPERLOCKING

MANUAL CLAMP

9ORN OUT

NG( E CESS

GAP FOUNDAFTERCLAMPING

H) H); A%AL),I,


22/40

< 9e3h6d: 1a? e37een S3ud 1a ari and Pane5


Signi!icant Not signi!

1a ari I@?r6?er 56cBin> @anua5 c5a@? ?5a=crea3in> 1a? , 96re 46rce need 36 eCer3 6n1un ;3ren>3h checB

H) H) A%AL) I


23/40

MATERIAL 9HY 9HY 9HY 9HY VERIFICATION

RESULT

17MATERIAL(OILCONTAMINATION REARFLOOR REARMBR CROSS6

OILCONTAMINATIO INRECEVINGLEVEL

ANTI RUST OILFOUND INMATERIAL

OK AS PERSTANDARDNO c @@!il6

87 PANELPROFILE FLAT

NESS>CONCERN INREAR FLOORREAR MBRCROSS

PANELPROFILE

FOUNDFLAT NESSFOUNDVARIATION

SPOTUNDULATION

INCOMING PART

SPOTLOCATION

SHIFT FROMIN PART

8 SPOTSLOCATED IN

STUD 9ELDLOCATION 7

NG(PROFILEFLATNESSUNEVEN DUETO SPOTUNDULATION17 STUD

FAILUREOBSERVEDON STUD9ELDEDABOVE THSPOT

87 STUD 9ELDGUNANGULAR

Y SETTINGCONCERN

H) H); A%AL),I,


24/40

*< 9a3eria5 : Rear Side 9 r 567er A;;= ?ar3 ?r64i5e 45a3ne;;



%< Pr64i5e !6und uneven, Due 36 S?63@i;56ca3i6n and Uneven In3er4erence


25/40

< 9a3eria5: OIL $6n3a@ina3i6n in ?ane5



ECce;; 6i5 5ead; 36 ;3ud 4ai5ure


26/40

DETERMINATION OF COUNTER MEASURES

MAIN

FACTOR

VERIFICATI

O

S7NO ASSUMED MAINFACTORS

ANALYSIS ANDVERIFICATION ITEMS

CAUSES IMPROVEMENT ACTIONS PR

1

Ma? (9!" i?

@ ill

a6Hi * @+ $@ %$ %? *a?$i?l a$i? ! l$

c-cl i?c!'+l

17 Lac ! a a" ? @@!? @ %$ l$i? "i - 7

87 Lac ! a a" ? @@!? *i * @+ $!" i? i'+ac @ !?

@ %$ l$i?

17 Ba@ic S %$ l$ i * +"ac ical

a a" ? @@ "ai

+la?? $ 787 F!c%@ !? @ %$ ail%" '!$ @ $!i?

? a i ali$a i!? !a&! ac !"@

2 Mac*i? (S %$G%? A? %la"i -

a7S %$ G%?a? %la"i - 0<$ " @ i?C!?c "?

17S %$ G%? a? %la"i -@ i? c!?c "? $% !&a@ +a? l +"! l%? ? a?$ c @@ a+$% ! @ %$ l$

a&a"i a?$ Ba@ R a"!!" A@@ '&l-

17S %$ G%? a? %la"ia c i? c!?c "?@ !

!c%@ $ !? 'ai? ac !"@c!? "i&% i? 7E Pa?@ %$ a+ Ga&a"i $& c*a? $87 Ba@ +"! l %?

ac !"@ c!? "i&% i!?@c* c $

3 M *!$ (Ma?%alcla'+ C!?c "?@a?$ S %$ Ga&a"iB%@* L!!@ ?i?a?$ +la-

a7 Ma?%al Cla'+@a++lica i!?

a?$ S %$Ga&a"i B%@*D @i ?c!?c "?@

17 S %$ %" Ma?%alcla'+@ ?! %ll-l!c $ a?$ cla'+ $l a$i? ! Ga+@7

87 S %$ Ga&a"i &%@*l!!@ ?i? c!?c "?@ $%

! +!!" a&a"i $ @i ?

17 P? %'a ic Cla'+@ !i'+l ' ? $ !" i'+"! i?"i i$i - i? @ %$ Ga&acla'+i? 787S %$ Ga&a"i A&@ c$ @i ? ! c*a? $ "!'

! Ca@ i"!? ! i'+"!



27/40


MAIN

FACTOR

VERIFICATION

S7NO ASSUMED MAINFACTORS

ANALYSIS ANDVERIFICATION ITEMS

CAUSES IMPROVEMENT ACTIONSPROPOSED

4 M *!$(Ma?%alcla'+C!?c "?@ i?@ %$ %"

a7 Ma?%al Cla'+@a++lica i!?C!?c "??@

17 Ma?%al cla'+@ !i?a" !% l a$i? !

cla'+ %? ? l!c i? 787 I'+"!+ " l!c i? a?$

%?l!c i? l a$@ !

Cla'+ *i $a'a$%"i? %?l!a$i? *a@@ '&l-

17 I'+l ' ? a i!? !P? %'a ic cla'+@ !i'+"! !"i'+"! i? **!l$i? ! cla'+@7

87 I'+"! @ i? !?@ i c* ? l!c i?a?$ %?l!c i? !cla'+@ @

5 Mac*i?(S %$ l$c!llc!?c "?@

a7S %$ l$ C!ll!"? !% a?$

a"c*i? i@@% @

17Ca"&!? D +!@i a?$l$ @+a "

acc%'%la i!? !? *@ %$ C!ll l a$i? !

a" ! @ %$ c!ll@%" ac a?$ a ?i?! @ %$ *!l$i? !"ca?$ " % ? a"c*i?a?$ +!!" l$@

17S %$ l$ C!llcl a?i? " % ?c-Da- i@ @c* $%li'+l ' ? a i!? a?$'!?i !"i? i *E c i TPMi'+l ' ? a i!?

6 Ma "ial( RRSi$ '&"L! " A@@-C"!@@ +a"LH>RH

a7 Ma "ial &a@+"! l %? ?

!" @ %$ * a$+!@i i!?i?

17 Ma "ial &a@ +"! l%? ? $% ! S+!i? " " ?c i? @ %$

l$ l!ca i!? $% !@+! 'i@@ l!ca i!? i?+a" l l

17 Ma "ial RR Si$M&R A@@- L! "c"!@@ +a" 6 @ %$@%" ac ! & 'a$

? &- a !i$i? *@+! i? " " ?c i

@ %$ l!ca i!?787 I? " "i? S+!

C/*%TER MEA,*RE IM(LEME%TATI/%S %$ 9 l$i?Fi %"


28/40

C/ %TER MEA, RE IM(LEME%TATI/%B !" C!?$i i!?

17 Ma?%al cla'+ – I'+"!+ " l!c i?

L a$@ ! Pa? l Ga+ c" a @ABNORMALITY D%"i? @ %$ G%?A? %la"i - ac*i? a?$ S i?

A " C!?$i i!

17 P? %'a ic cla'+@– G!!$Cla'+i? P" @@%"

87 Ri i$ a?$ I'+"! $ Cla'+i?:7 GAP &> Pa? l a?$ @ %$

R $%c $

Ma?%al Cla'+i?O+ "a i!? i? S %$

Fi % "

Fi %



29/40

C/ %TER MEA, RE IM(LEME%TATI/%B !" C!?$i i!?

17 S %$ 9 l$ Ga&a"i 'a$ ! FRP

Ma "ial87 Hi * T*ic ? @@:7 S %$ l$i? l!ca i? B%@* @

$ i? FRP Ma "ial7 F" % ? S %$ Ga&a"i B%@*

l!!@ ?i? a?$ C!' @ !% i@@%37 L a$@ ! S %$ G%? A? %la"i -

ac*i? a?$ S i? 7.7 Ca%@ !" S %$ +!!" l$ a?$

A " C!?$i i!

Fi %

17 Ca@ I"!? Ma "ial S l cF"a' S %$ Ga&a"i F!" LH>RC! " S %$@7

87 Ri i$ i? D @i ? a?$ S %$ GaB%@* @ Fi"'l- l$ $ i? ?Ga&a"i7

:7 S %$ &%@* C!' @ !% a?$ +i@@% R @!l $

FRP TO CASTIRON

C/*%TER MEA,*RE IM(LEME%TATI/%


30/40

% , ( % %

HI H ,(EE" ,T*" *% HA%"IIM(ACT,

8E) LEAR%I% ,

Tr -n-n! n < rene== =e==-,t e proce== p r ete

Inte!r-t

TRAINING AND A9ARENESSSESSIONS

FAILURE MODE (TEAMANALSYIS

C/*%TER MEA,*RE IM(LEME%TATI/%


31/40

, (

'r -n =tor -n! n >no<=: r-n!

8E) LEAR%I%

Tr -n-n! n < rene== =e==-,t e proce== p r ete

Inte!r-t

TRAINING AND A9ARENESSSESSIONS

FAILURE MODE (TEAM ANALSYIS BYNEGATIVE VALIDATION

17.04.15

C/*%TER MEA *RE IM(LEME%TATI/%


32/40

M'R A,,);,I"E RR CR/?76454 3761R@

"emp action01223 mallet check in process and /ualit) gate to prevent out !low.erm action 0Supplier spot need to shi!t 42mm !rom current position +.5A "eam Bod) .'-

1., pp -er =pot =:-fte n


33/40

, (B !" C!?$i i!?

17 MATERIAL – SPOTINTERFERNCE IN STUDLOCATION

87 FREQUENT STUD FAILUREON THIS LOCATION

A " C!?$i i!

17 MATERIAL– IMPLEMENTASHIFTING DOINCOMING PA

87 ACTION IMPLSUPPLIER ENTEAM

M CHANGEIMPLEMENTATION

IN MATERIAL



34/40

, (B !" C!?$i i!?

17 REAR ABS COVER M. STUD9ELDED ON TOP THESPOT 9ELD7

87 POOR STUD 9ELD FUSIONDURING STUD 9ELDING

:7 FREQUENT FAILURE

A " C!?$i i!

17 REAR ABS COVE9ELDED IN LOCAPER M CHANG

87 STUD 9ELD QUAIMPROVED

:7 NO STUD FAILU7 NO SPOT INTER

STUD LOCATION

M CHANGEIMPLEMENTATION

IN MATERIAL


35/40

RESULT CHECK

CHECK THE RESULT; MONITORING


36/40

$A%#15 &E'#15 MAR 15 A(RIL#15 MA)#15 $*%E 15 $ ;15 A !;15 ,ep;150

1

2

3

4

5

6

7

8

9

7

8

5

6

7

0 0 0 0

STR Ou34567 8A S $OVER STUD !AILURE (/ .)

96n3h

#O O! $ARS

REAR ABS COVER STUD FAILURE ATTCF(RESULT CHECK

S a?$a"$i a i!? R!! Ca%@ C!? "!l


37/40

This is TpmPoin t !!!

@

T"ai?i? ! all O? S %$ l$ T+' – KEYFOCUS ON STUD GUN AND COLLET DAILYTPM

Dail- C* c c!? "' &- T' '& "@ ! +" ? c!lla?$ a"c*i?

+ St $ $i ti $ / t 0 th $


38/40

I3e@

S3andard i a3i6n

S?63 ;hi43ed 36%&@@

$han>e in;u??5ier ?ar3

T6 e5i@ina3e 3he ;?637e5d in3er4erence in

;3ud 56ca3i6n

SUDEES/0RAE#DRA#

U#E’%& SU !LOO

TP9 checB?6in3 <

STUD ELD 1U#$OLLET

$O#!IR9ATIO#

SUDEES/ U#E %& SU !LOOR

STUD e5dO?era3i6n;3andard;

TO Av6id ;3ud 4ai5uredurin>?r6ce;;

RA A1OPAL 9AY%& SU !LOOR

Educa3i6n

O?era36r3rainin> and

A7arne;;

T6 i@?r6ve Bn675ed>e6n ;3ud 7e5d 4ai5ure

@6de;

SUDEES/0RAA1OPAL

9AY %& SU !LOO

/6ri 6n3a5de?56=@en3

!RO#T!LOOR

T6 Preven3 ;3ud 7e5d!ai5ure

SUDEES/ U#E%& SU !LOOR

+ , Sta-$ar$i.atio- a-$ /o-tro0 metho$

ReBect-on of t:e Act- -t ?Le rn-n!@


39/40

,*"EE,H; In - - c p - -t-e= of (ro e ,o -n! 8 -Den M-n n Te to &I%,/L*TI/%,

RAM*8*MAR; //" TEAM ACTI+IT) MA%) I"EA, E%ERATE &R/M TEAM

+A,*; I port nce of Te or> 'r -n ,tor -n!


40/40

B!$- @*!+Thank you very much for attention

qc project - copy (2)

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