qc story- battery mounting
TRANSCRIPT
1AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Concern Resolution Process for In-house Manufacturing
QC Story
2AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
QC STORY PROJECT
PROJECT TITLE :-Elimination of Battery mounting not done
concern in Alfa Assy line Mahindra and Mahindra Ltd, Zaheerabad Plant, Vehicle PU
Plan Actual
Start Date 08.10.12 18.10.12
Completion Date
04.05.13
Current Status:
CLOSED
3AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Phase II – QC Story• Team Information• Step1: Select the Theme• Step 2: Justify the choice• Step 3: Understand the current situation• Step 4: Select Targets• Step 5: Analysis (Level 1 Analysis)• Step 6: Implement corrective measures• Step 7: Confirm the Effects• Step 8: Standardise• Step 9: Summarise & Plan future actions• Guidelines to user
4AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Cross Functional TeamNo Descripti
onName Designation Dept Phone Email
1 Team Leader
K. Vamsi Krishna
Graduate Engineering Trainee
Vehicle PU 8008491307 [email protected]
2 Mentor Mr. Abburi Purna
Asst. Manager Vehicle PU 9676197179 [email protected]
3 Member 1 K Chaitanya Kumar
Asst Manager Vehicle PU 9652262699 [email protected]
4 Member 2 D Suresh Manager Vehicle PU 9949396000 [email protected]
5 Member 3 K Chakravarthy Manager Vehicle PU 9989922011 [email protected]
6 Member 4 Gr suresh Dy. Manager Vehicle PU 9866287959 [email protected]
7 Member 5 Bhanu Prakash Asst Manager SQA 9393315415 [email protected]
5AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
1. Select the Theme
Brief description of Problem
Around of 180 veh per month are reworked in buy-off and hold rework regarding battery mounting.
What: Battery mtg not done
Where: In Alfa (3 wheeler) Mechanical assembly Line.
When : Identified while assembling
Who : Reported by the stage operator and intermediate Buy Off operators
Why :
How: * It got noticed during the inspection at buy off stage * Around of Avg 180 veh per month are reworked in buy-off and hold rework regarding battery mounting.
6AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
2a. Justify the choice (reasons)PARETO OF Battery mtg not done concerns over
PERIOD APR’12 TO Oct’12
• Vehicle loss getting reworked for battery mtg not done : F13 ( High Occurrence)
• High severity rating: 8
7AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
2b. Immediate Containment Action
• Rework for Battery mtg not done will be done at IP buy-off if rework doesn’t complete in time vehicle is reworked at hold rework area.
8AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
3. Understand the current situationProcess flow of Alfa Vehicle on Mechanical Conveyor
9AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Vehicles get reworked due to Battery mtg not done are around 180 veh /month
Total Vehicle reworked in F-13 (Apr’12 to Oct’12)= 1252 veh
3. Understand the current situation
10AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
4. Select TargetPresent
Level:
Target:
1689 vehicles reworked in F-13( Apr’12 to Oct’12)
Zero Vehicle loss in next months, i.e.from May’13G
OO
D
11AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
5. Analysis 5.1 Identify possible causes:
MACHINE MAN
METHOD MATERIAL
Battery tension rod mtg hole offset
Battery tension rod mtg brkt nut portion bur
Operator Fatigue
Bundy tube fouling to Battery
Tray mtg hole area Dent on Body
operator not followed SOP
inadequate SOP
Tension rod threads not projecting out
Tension rod thread bur/Damage
Gun malfunction
Sealant excess on Battery mtg area
SOP not there
L Bracket bend/ Position Shift
L Bracket miss
Driver seat rod fouling to battery
New operator
Battery tray wrong part
Tray mtg side brkts bend/ Position shiftBattery brkt mtg nut slip
L brkt hole miss
Tension rod mtg hole miss on body
Tray mtg hole miss
Tray mtg bottom extended part to enter body hole operation miss
Tray crack
Tension rod mtg battery brkt hole miss
Tension rod mtg battery brkt hole offset
FRL malfunctioning
SOP key point miss
Tool worn out
Wrong socket used
Wrong nylock nut used
Operator skill
Battery tension rod adjustment not done
Battery NSP on tray
Tray wrong part
Wrong tension rod used for different models
Battery mtg area uneven/major dent
Battery wrong position placed
Wrong battery usage for different models
Battery tension rod mtg brkt bend/twist
Tension rod mtg battery brkt hole undersize
No correct process is defined
Wrong process used in achieving
Battery tension rod mtg brkt nut mtg brkt bend/damage
Battery mtg not done
12AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
5. Analysis
S. No Probable Cause
1 Operator Fatigue
2 L Bracket bend/ Position Shift
3 Tension rod mtg battery brkt hole undersize
4 Tension rod threads not projecting out
5 Bundy tube fouling to Battery
6 Battery tension rod mtg brkt bend/twist
7 Sealant excess on Battery mtg area
8 Tray mtg side brkts bend/ Position shift
Probable Causes: (Based on experience & Knowledge) Eight Probable causes selected out of 44 possible causes for testing i.e. establishing root causes.
13AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
1Operator Fatigue
Operator has to take the battery(Wt:15kg’s) from the pallet at certain height and place it on the vehicle as the bending and weight Holding to 140 veh daily leading to fatigue.
Hypotheses valid
5.2 Confirm the probable cause:
5. Analysis
14AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
2
L bracket Bend/Position shift
The L brkt position is getting shifted at the supplier end while L brkt placed in fixture its position is getting shifted while welding the bracket to the body, which in turn leads to the
Tension rod threads not projecting outside the battery mtg bracket hole.
Hypotheses valid
5.2 Confirm the probable cause:
5. Analysis
15AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
3Tension rod mtg battery brkt hole undersize
In mounting the Battery bracket , tension rod may not enter the battery brkt, as its hole is undersize leading the battery mtg not done
Hypotheses Invalid
5.2 Confirm the probable cause:
5. Analysis
16AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
4
Tension rod threads not projecting out
Dimension of the tension rod mtg adjuster rod and plain rod variation leading to tension rod threads not projecting out, leading to Battery mtg not done
Hypotheses Invalid
5.2 Confirm the probable cause:
5. Analysis
17AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
5Bundy tube fouling to Battery
Bundy tubes which is mounted to TMC, in that T-joint mtg bundy tube coming out of the guided side brkts and obstructs the Battery mtg.
Hypotheses valid
5.2 Confirm the probable cause:
5. Analysis
Improper bending profile of the Bundy tube projecting out of the tray stopper and fouling to battery leading to battery mtg not done
Improper bending profile of the Bundy tube projecting out of the tray stopper and fouling to battery leading to battery mtg not done
18AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
6Battery tension rod mtg brkt bend/twist
Battery tension rod mtg Brkt if twisted leads to mtg hole offset and battery mtg not done.
Hypotheses Invalid
5.2 Confirm the probable cause:
5. Analysis
19AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
7
Sealant excess on Battery mtg area
Excess sealant application at the Battery tray mtg area leads to Battery tray NSP, and battery mtg not done.
Hypotheses valid
5.2 Confirm the probable cause:
5. Analysis
Unwanted sealant at the battery tray mtg area leads to tray NSP into its mtg hole and leading to Battery mtg not done hence Hypothesis valid
Unwanted sealant at the battery tray mtg area leads to tray NSP into its mtg hole and leading to Battery mtg not done hence Hypothesis valid
20AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
8
Tray mtg side brkts bend/ Position shift
Battery Tray mtg brackets position shifted leads to Tray not seated properly and bundy tubes projects outside leading to Battery mtg not done
Hypotheses valid
5.2 Confirm the probable cause:
5. Analysis
21AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
5. Analysis
S. No Probable Cause Remarks
1 Operator Fatigue Hypotheses valid
2 L Bracket bend/ Position Shift Hypotheses valid
3 Bundy tube fouling to Battery Hypotheses valid
4 Sealant excess on Battery mtg area Hypotheses valid
5 Tray mtg side brkts bend/ Position shift Hypotheses valid
Following are the Probable causes identified for the conveyor breakdowns
5.2 Confirm the probable cause:
22AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
WHY - WHY Analysis
S. No Valid Probable Cause
WHY WHY WHY
1 Operator Fatigue
Operator has to bend and lift the Battery from the pallet(15 kg’s weight)
Because there is no alternative mechanism, he places manually
Due to the design limitations of the working area
2 L Bracket bend/ Position Shift
Position shifted while welding the brkt to the Body
While welding the Brkts to the body in fixture, twisting of brkt occurs
Due to the fixture limitations while welding Brkts
5.3 Identify the root causes:
23AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
WHY - WHY Analysis
5.3 Identify the root causes:
S. No Valid Probable Cause
WHY WHY WHY
4 Bundy tube fouling to Battery
Bundy tube projecting out of the side brkts and fouling to battery
In design the bending angle and degrees not specified only supplier supplying based on master sample.
Master sample variation at supplier end
5 Sealant excess on Battery mtg area
Sealant provided on the Body as surface at that Tray area as the area is uneven
As the part is welded on the body for supporting
Due to the design
6 Tray mtg side brkts bend/ Position shift
Position shifted while welding the brkt to the Body
While welding the Brkts to the body in fixture, twisting of brkt occurs
Due to the fixture limitations while welding Brkts
24AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
6. Implement the corrective measures6.1 Actions Decided
Root Cause Action Plan Target Dt
Resp. Status
Operator Fatigue
Operator fatigue can be eliminated completely by providing the pneumatic fixture for lifting the battery.
10.01.13GR suresh/
K. ChaitanyaClosed
L Bracket bend/ Position Shift
The bracket shifting is completely eliminated by providing the magnetic surface area over the fixture, which eliminates the brkt position shifting/bend
13.01.13 Sarapu BhanuClosed
25AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
6. Implement the corrective measures
6.1 Actions Decided
Root Cause Action Plan Target Dt
Resp. Status
Bundy tube fouling to Battery
Raised the DCR and corrected the bending profile from 49.52 to 38.87 for avoiding the Bundy tube to contact with tray and Battery
15.04.13 K.vamsi/VGS EN under progress
Sealant excess on Battery mtg area
Permanently delete the sealant application at battery tray mtg area
10.09.12Manikappa/
YSN Murthy
Closed
Tray mtg side brkts bend/ Position shift
The bracket shifting is completely eliminated by providing the magnetic surface area over the fixture, which eliminates the brkt position shifting/bend
13.01.13 Sarapu Bhanu Closed
26AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Root Cause Action Plan Target Dt Resp. Status
Operator Fatigue
Operator fatigue can be eliminated completely by providing the pneumatic fixture for lifting the battery.
10.01.13GR suresh/
K. ChaitanyaClosed
6. Implement the corrective measures
By providing the Pneumatic fixture the operator stress in lifting the battery and placing on vehicle is completely eliminated
By providing the Pneumatic fixture the operator stress in lifting the battery and placing on vehicle is completely eliminated
27AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Root Cause Action Plan Target Dt
Resp. Status
L Bracket bend/ Position Shift
The bracket shifting is completely eliminated by providing the magnetic surface area over the fixture, which eliminates the brkt position shifting/bend
13.01.13 Sarapu Bhanu Closed
6. Implement the corrective measures
The bracket shifting is completely eliminated by providing the powerful magnet which prevents the brkt shift/Bend during welding to body
The bracket shifting is completely eliminated by providing the powerful magnet which prevents the brkt shift/Bend during welding to body
28AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Root Cause Action Plan Target Dt Resp. Status
Bundy tube fouling to Battery
Raised the DCR and corrected the bending profile from 49.52 to 38.87 for avoiding the Bundy tube to contact with tray and Battery
15.04.13 K.vamsi/VGS EN under progress
6. Implement the corrective measures
Bundy tube fouling to Tray eliminated by correcting the bending profileBundy tube fouling to Tray
causing to tray crack
29AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
6. Implement the corrective measures
Design change request - DCR
Design change request - DCR
30AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Root Cause Action Plan Target Dt Resp. Status
Sealant excess on Battery mtg area
Permanently delete the sealant application at battery tray mtg area 10.09.12
Manikappa/
YSN MurthyClosed
6. Implement the corrective measures
In order to eliminate the issue of battery tray not fitted in Alfa Model due to sealer bead obstructionWe have taken the below actionConcern: Battery tray Not Fitted due to excess Sealer
PCA: Sealer cutting at Battery Tray BracketCut off No: From 10.09.2012 Second shift vehicles6536-478 ( Alfa Pass ) & 6536-244 ( Alfa L\C)
31AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Root Cause Action Plan Target Dt Resp. Status
Tray mtg side brkts bend/ Position shift
The bracket shifting is completely eliminated by providing the magnetic surface area over the fixture, which eliminates the brkt position shifting/bend
13.01.13 Sarapu Bhanu Closed
6. Implement the corrective measures
The side bracket shifting is completely eliminated by providing the powerful magnet which prevents the brkt shift/Bend during welding to body
The side bracket shifting is completely eliminated by providing the powerful magnet which prevents the brkt shift/Bend during welding to body
32AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
7. Check & confirm the results & effects7.1 Verify Results:
7.2 Full Scale Implementation plan:
Root Cause Action Plan Target Dt Resp. Status
Bundy tube fouling to Battery
Raised the DCR and corrected the bending profile from 49.52 to 38.87 for avoiding the Bundy tube to contact with tray and Battery
15.04.13 K.vamsi/VGS Closed
Sealant excess on Battery mtg area
Permanently delete the sealant application at battery tray mtg area 10.09.12
Manikappa/
YSN Murthy
Closed
Tray mtg side brkts bend/ Position shift
The bracket shifting is completely eliminated by providing the magnetic surface area over the fixture, which eliminates the brkt position shifting/bend 13.01.13 Sarapu Bhanu
Closed
After Implementing corrective actions, like tray mtg area sealant deletion, Bundy tube profile correction and gauge correction at supplier end completely resolved the issue.
33AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
7.3 Tangible Benefits
1.Elimination of V1 Concern 2. Improvement in quality indicators (FRC, FBO & DPV)3. Rework cost saved (Avg 180veh/month-Rs. 38,880/- per year)4.Rework at hold eliminated.5.Customer quality increases6. Improved Delivery performance in PDI
7.3 Intangible Benefits
Morale of the operator is increased.
Customer satisfaction increases
7. Check & confirm the results & effects
34AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
8. Standardisation8.1 Updation of documents:
8.2 Training:
8.3 Additional Audit / Check
DCP documents PFC,PFMEA, CP & SOP updated.
Drawings updated.
Process sheets updated.
Concerned operators are made familiar with the system regarding its function, operation
FTG Audit
35AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
9. Summarise & Plan future actions
9.2 Horizontal Deployment:
9.3 Lessons Learnt:
9.1 Conclusion:
By doing the several analysis, concluding the results from analysis the top FBO effecting concern is thrown out completely.
TGR: Implementing corrective actions, like tray mtg area sealant deletion, Bundy tube profile correction and gauge correction at supplier end completely resolved the issue.
TGW: Nil
Horizontal deployment can be applied for all 3-wheeler model manufacturers.
Information shared with HARIDWAR also.
36AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Thank You