WIS CONTROL PLAN FOR VEHICLE AGGREGATES

Radha.H *, R.V.Praveena Gowda**, Shruthi H.R***

*Faculty, Department of Industrial Engineering & Management, DSCE, Bangalore, Karnataka-560078, India **Professor, Department of Industrial Engineering & Management, DSCE, Bangalore-78, India. *** Student, Department of Industrial Engineering & Management, DSCE, Bangalore-78, India. *ID: hhradha@gmail.com, **ID: praveena_gowda@rediffmaill.com, ***ID: hr.shruthi11@gmail.com

Abstract Medium Duty vehicle (MDV) assembly is a major concern in a leading Truck Manufacturing Company. There are 37 stages of operations in which components are assembled at different levels to give the final assembled vehicle. Tool Work Instruction Sheet WIS and control plan was two different processes which were carried out manually and separately. It takes approximately 3 hrs/chassis to complete all 37 stages in MDV from the observation. In this case, the drawbacks of the WIS tool had affected in arriving the final assembled product in terms of process incapability i.e. some of the process components (Axle Shaft, Rear Hub etc) were incapable of meeting the design standards or specifications and also delay in time due to the control plan action was taken after the deviations have occurred in each stage. The Work Instruction Sheet Control Plan (WISCP) which was successfully implemented and developed for 8 different models of varying characteristics. This WISCP tool minimized the time to 2.75hrs/chassis and wastages in the assembly line. The process owners follows the tool everyday so that the process consistently work all the time and to standardize a process, by ensuring operators are consistently performing the same tasks and procedures which leads to reduced variation within a process. The tool also resulted in reduced incapability of few processes such as axle shaft, rear hub etc by achieving the desired process capability indexes (Cpk) (1.333min) according to the requirement. Keywords: Work Instruction Sheet, Control Plan, Process Capability, design standards, deviations.

Enterprise resource planning (ERP) integrates internal and external management information across an entire organization, embracing finance/accounting, manufacturing, sales and service, customer relationship management, etc. ERP systems automate this activity with an integrated software application. Its purpose is to facilitate the flow of information between all business functions inside the boundaries of the organization and manage the connections to outside stakeholders [3]. ERP systems can run on a variety of hardware and network configurations, typically employing a database as a repository for information [4]. II PROBLEM STATEMENT The problems were identified at assembly areas of vehicle aggregates Truck Manufacturing Company. The existed Work Instruction Sheet had many drawbacks in MDV assembly area in which process owners find difficulties to operate upon it. This centralized WIS is a major hurdle to carry out operations in each stage of MDV. Earlier control plan was referred only after post operation that leads to rejection of components. Hence there is a requirement to develop a new format of WISCP for individual stages in order to avoid rejections at preliminary stages. III OBJECTIVE OF THE PROJECT To overcome the above stated problem certain objectives were framed for this project to achieve accurate results and efficient productivity. 1. To study the various processes which are involved in assembly sections. 2. Understand material flow information for vehicle assembly. 3. To collect the data requirements for WIS cum control plan. 4. Preparation of WIS for all the stages in MDV for different models. 5. To suggest and implement an appropriate quality tool for problem reduction.

1 INTRODUCTION The components are assembled in different stages as per the stipulated process to built in quality, consistency and avoid repetition of work at downstream process of viewed assembly. Such elemental details of process are mentioned in work instruction sheet control plan which will assist the process owners to accomplish the task as per the specification at each stage. The Work Instruction Sheet (WIS) enables the operators to observe a production process with an understanding of how assembly tasks are to be performed. Work Instructions are usually positioned and displayed near tasks that require attention and precision to detail. The operator checks for the activity details in the WIS & performs the activity as per the guidance in the Assembly line [1]. Control Plan is a management tool to identify and monitor the activity required to control the critical inputs or key outputs for a process so the process will continually meet its product or service goals. Control plans are usually monitored at least by Quality Assurance, departments using inspection procedures and sometimes using quality function deployment methods. Control charts are typically used in a control plan to monitor items [2].

IV LITERATURE SURVEY 1) Methods of Operating Procedures AUTHOR(S) Enrick

(Enrick, 1974) [5] Have published a journal about different methods of operating procedures in an assembly line. The author Focuses on the layout, prescribes operating methods and time allowances established for assembly-line stations. 2) Usage of Tools and Methods of ERP in Planning Bhagwani (Bhagwani, 2009) [6] have done a project describing the features, tools of ERP system and also methods to plan in industry using this software. This project gives an overview of the Systems Applications and Products in Data Processing (SAP) Enterprise Resource Planning (ERP) implementation roadmap and tools that make up a complete implementation method to allow any organization to plan and execute the implementation of SAP ERP software. 3) QMS ISO/TS 16949 Requirements for Work Instruction Sheet [7] (Clause 7.5.1.2) Have documented work instructions, accessible at work stations, for all employees responsible for processes impacting quality. Jon Miller [Jon Miller, 1993] [8] describes that Standard Work is Kaizen Instruction for Managers. it includes information about tools used in that stage with their description and tool codes, date of release and revised, approval date, special and safety instructions, Work descriptions, quality check, part number and description, operation number and name etc. 4) QMS ISO/TS 16949 Requirements for Control Plan [7] it includes the information that describes the product characteristics and use of monitoring and measuring devices. 5) Reaction Plan Requirements [9] (Clause 8.2.3.1) Perform process studies of all new manufacturing (including assembly and sequencing) processes) to verify process capability & to provide additional input for process control 6) Elements of a Control Chart As per Statistical Process Control (SPC) reference manual [July, 2005] [10] developed by Ford Motor company, and General Motor Corporation V DESIGN METHODOLOGY Stage1: The vehicles are manufactured in MDV assembly Shop4. MDV conveyor Manufacturing facility is capable of producing 44 vehicles per day in two-shift operation. The plant produces around 14000 vehicles per annum. MDV assembly is pioneer in manufacturing facility is capable of assembling various models from passenger to mining in a single conveyor .The MDV assembly is mainly categorized under the Frame assembly with a manual conveyors, Vehicles assembly conveyors, Sub assembly, Engine dressing, FES dressing and Road Test Preparation Area. The first step involves a basic understanding of the stages of operating processes before identifying the problem The second step followed in WIS was preparing flow charts which depict the operation sequence, activities performed and sources of variation in each stage. Starting with frame assembly to sending the chassis for road. Frame assembly consists of five stages of assembling Frame side member and cross member, which forms the basic structure of chassis. Each and every activity is equally distributed in the stage and is being certified by the associates for fitness and completion. Before feeding the frame to chassis conveyor the same is being checked for 100% worthiness and passed by Quality Engineering department.

Stage 2: Chassis conveyor consists of thirteen stages, which roll out a complete chassis. The various activities that go into building a complete chassis are equal divided into thirteen stages in a sequential manner. Along with a chassis a self-certification card is placed. Each activity done on a chassis is self-certified by the concerned associates any deviation is mentioned in the card for further action. The key parameters are mentioned with a symbol Q+ and QP for extra attention during assembly. Individual associates meeting the expected quality standards certify each and every activity. Once the vehicles gets of tracked from the conveyor the chassis is checked for any abnormality by going through the card. On noticing any such abnormality the chassis are toed to Road Test preparation Area (RTP).The vehicle are than cleared for all the shortfalls in the conveyor and then sent for road test to check the performance and reliability of the product. The vehicles, which are produced, are subjected to stringent quality checks before being delivered to customers. There are three levels of inspecting procedure. As mentioned below Complete inspection at Road Test preparation area Inspection & Testing by Road test & Testing on Roller test bench Pre delivery inspection The chassis certified by the executive in RTP is sent for Road test. The test is being done in a closed roller test bench. The chassis is run for 15km under various simulations. Any abnormality seen is recorded in the card by the road test inspectors. The chassis after completion of road test is sent to PDI (Pre Delivery Inspection). The associates go through the various points mentioned in the card by the road test inspectors and attend to them. The chassis is checked finally for all the functional and aesthetics points and ok for the dispatch. A cross checks audits is being conducted by the CQE (Corporate Quality Engineering) dept in samples. Any abnormality found is crosschecked for the entire batch of chassis and clearance is given for final dispatch. Stage 3: The data is collected through process sheet to prepare Work Instruction Sheet (WIS). Process Sheets are designed to evaluate several processes of a component which is a step by step procedure of each and every process involved to suit the final requirement. The optimum result can be obtained by the study and analysis of the processes involved and preparing the process sheet for the respective component. Process Sheets for each component are designed using Enterprise Resource Planning. The existing process sheet consists of title of assembly stage, machine no, operation steps in detail and the tools necessary for the assembly with their codes. The process sheet once developed is also fed into ERP system for making the work easier so that the process owners finds and access easily. The following Fig 1and Fig 2 depicts about the process sheet

operating instructions and control plan information to refer whenever there is a deviation and also safety instruction in which the operators should be alert

Fig 1 Process Sheet generated showing Operation Sequence Description

Fig 3 New Format of combined WIS & Control Plan

The WIS cum Control Plan was prepared for the seven models and the complete description of the combined new format for all the 37 stages for each models are prepared. VI PROCESS CAPABILITY ANALYSIS STUDY The second analysis part carried out for implementing the WISCP was process capability study. Many components of few processes were incapable of meeting the engineering specifications. By implementing quality control tool like control charts the processes now consistently work to get the desired output in that stage. The control chart chosen was variable data chart since the values observed are of varying measurement. The following Fig 4 is an X-Bar R chart for the component Axle Shaft which is used in Axle Assembly stage of MDV.

Fig 2 Process Sheet generated showing tool description

The next step was carried out in creating a database for control plan with reaction plan. Control Plan is the measures specified by Quality department to be done when there is any deviation in the pecified process. Control plan includes product characteristics, ample size, and also measuring technique if any process deviates rom the standards. Reaction Plan is the measures to be taken for ectifications of the Process deviations. The new combined Work Instruction Control Plan format is hown in Fig 3 which includes part number and description. the operation description with the stage in which it is operated, pictorial representation of the operation, tool information,

Table 1 Range of values taken for Axle Shaft

CLR= R UCLR= D 4R D3, D4 = Multipliers of R- Bar used to calculate the lower and upper control Limits, respectively for ranges. LCL R =0 CLR = 0.0042 UCLR =0.0089 D3 = 0, D4 =2.11 for 5 subgroups from statistical table 1

=R
Fig 4 R Chart curve with 3 Specification Limits

d2

R = The average range of a series of subgroups of constant

size. d2 = A divisor of deviation.

Process Capability (Cp) (USL-LSL)/6 USL = the upper Engineering specification limit. LSL = the lower Engineering specification limit. = Standard Deviation. Cp = 55.030-55.011 = 0.019 = 1.75 6(1.805*10^-03) 0.0108 Process Capability Analysis (Cpk) CPL = (X-LSL) 3 CPL=the lower capability index. LSL = the lower Engineering specification limit. Fig 5 Histogram depicting the Range of values is within Limits & Frequency = Standard Deviation. CPL = (55.0198-55.011) = 0.0088 = 1.614 3(1.805*10^-03) 0.00545 VII CALCULATIONS CPU = (USL-X) X For first subgroup = 55.019+55.021+55.018+55.022+55.020 3 = 55.0200 CPU = (55.030-55.0198) = 0.0102 = 1.871 5 3(1.805*10^-03) 0.00545 CPU=the upper capability index. R For first subgroup = 55.022-55.018= 0.004 USL =the upper Engineering specification limit. X= 55.019+55.020+55.019+55.021=55.0198 = Standard Deviation. 30 Cpk = Minimum(CPL,CPU) = Minimum(1.614, 1.871) R = 0.004+0.004+0.003+.0.003 = 0.0042 =1.614 30 Cpk = the capability index for a stable process. X-Bar Chart: LCL X= X A 2R The control charts were successfully implemented which reduced the incapability of the process so that the CLX= X operations are consistently carried out in an assembly line. UCLX= X+A2R A2 = A multiplier of R used to calculate control limits for VIII ANALYSIS AND RESULTS averages. LCL X = 55.0173 The following graphs are plotted taking X-axis as the different stages in MDV and Y-axis as the time in minutes for carrying the CLX= 55.018 activities of each stage. Here only few stages are taken for UCLX = 55.0222 consideration. The following Fig 6 depicts the time in minutes A2 = 0.58 for 5 subgroups from statistical tables. taken for individual stages in MDV before implementing the new LCL R= D3 R tool.

The values plotted are observed range of values which are taken for 6 days with each day 25 observations and divided into 30 subgroups with 5 observations within each subgroup. The engineering specification limits were given prior. Then the histogram (Fig 5)was drawn which specifies that the range of values taken are within the upper and lower Engineering Specification Limits.

R used to estimate the process standard

= 0.0042 = 1.805*10^-03 2.326 d2 = 2.326 for 5 subgroups from statistical tables.

reduced total time to complete all the 37 stages of MDV production from 3hrs/chassis to 2.75hrs/chassis. IX CONCLUSION Work Instruction Control Plan acts like a tool which enables the process owners to perform consistently. The stages of operations are also carried out accurately which by analysis showed the process capability meeting the standard of 1.33(Min) according to design specifications. It is evident that WISCP has been successfully implemented in the assembly line and can be extended to all other assembling areas. Now the total time taken to complete all the 37 stages in MDV assembly has been reduced to 2.75 hrs which shows the improvement in production performance. REFERENCES
[1] http://www.chartitnow.com/Work_Instructions.html [2] http://it.toolbox.com/wiki/index.php/Control_Plan [3] Bidgoli, Hossein, The Internet Encyclopedia, John Wiley & Sons, Volume 1, 2004, Inc. pp. 707. [4] KhosrowPuor, Mehdi, Emerging Trends and Challenges in Information Technology Management. Idea Group, 2006, Inc. pp. 865. [5] Enrick, Norbert Lloyd, Assembly Line Balance, Industrial Management; Jun74, Vol. 16 Issue 6, pp.7. [6] Anil Bhagwani, Critical Success Factors In Implementing SAP ERP Software, an EMGT field project,University of Kansas,2009,pp.5. [7] Quality Management Systems Particular requirements for the application of ISO 9001:200 for automotive production and relevant service part organizations,ISO/TS 16949 Manual, Second Edition, 2002, pp.21. [8] http://www.gembapantarei.com/Standardized%20Work%20Instruction %20Sheet%20%28SWIS%29.pdf [9] Quality Management Systems Particular requirements for the application of ISO 9001:200 for automotive production and relevant service part organizations, ISO/TS 16949 Manual, Second Edition, 2002, pp.28. [10]DaimlerChrysler Corporation, Ford Motor Company, and General Motors Corporation, Statistical Process Control , Second Edition, July 2005,pp.48.

Fig 6 Bar chart showing time consumed for stages before WISCP in MDV

The following Fig 7 depicts the time in minutes taken for individual stages in MDV after implementing the new tool.

Fig 7 Bar chart showing operating time consumed for stages before WISCP in MDV

By comparing the two graphs above there is a reduction of time for 5 stages of assembly of about 15 minutes which leads to the