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Sl no. Inspection parameters Specification Obs 1 Mounting Holes C.

D 2 Pattern not OK Various elements 3 Poor fettling Extra material 4 Multi Cavity Varriation Profile and radius Profile no Verification after Gauge introduce Multi Cavity Varriation Profile and radius No fouling

Specification Observations Results C.D OK O Various elements OK O Extra material OK O Profile and radius Profile not ok & undersize X cation after Gauge introduced Profile and radius No fouling during assly. OK

Why. Why. Why. Why. Why.


Target

Machining Shift Pattern Not ok Poor fettling Multi cavity varriation


30 25 20 24 18 15 10 0 10 5 0 Nov'11 Dev'11 Jan'12 10 24 18

Nov'11 Dev'11 Jan'12 Feb'12

0 Feb'12

Plant: NHFIPL

STANDARD KAIZEN / PDCA (Chronical Problems)


FI(Focused Improvement) AM(Autonomous Maintenance)

Department/MBU Machine/Line : Project Code Cost Center

Quality Engine Line 613


PD(People Development) ENV(Environment)

Theme : To resolve Water pmp support fouling during engine assly. Part no.4840211
SAF(Safety) CD(Cost Deployment) WO(Workplace Organization) PM(Professional Maintenance) QC(Quality Control) L&CS(Logistics & Customer Service)

EEM(Early Equipment Management) EPM(Early Product Management)

PLAN
Unskilled Manpower

MAN
Fitment Orientation

Machine

ROOT CAUSES
Not Applicable
Water pump support fouling with Gear Case during sub assembly with engine block at station - 5 observed by Assembly associate occuring randomly leading to the loss of 52 trators

10h DO

Containment Action:- 1) Available Stock Segregated with Support of Mockup assembly of Engine ok part supplied on the line.
2) Receiver Gauge introduced for fouling to improve detection at supplier end. From 20/01/2012

Support Mounting hole CD not ok

Fouling

Excess Parting Line in gear Case

CD of Engine Poor Fettling in Water Pump Support

Process Sequence Wrong

Outer profile not ok

Material

Method

Descprition of the phenomenon ( 5W-1H)


Problem - Fouling during assly.( Water Pump Support- Supplier Versatile)
What When Where Who Which How -

Permanent Corrective Action:-

Water Pump Support Fouling with Gear Case. During water pump support sub assly.with Engine block on 5th Nov 2011 in A-Shift At Engine assly.station-5 assly. Associate Randomly Water pump support not sitting properly for the assembly leading to the loss of 52 tractors
Water pump support fouling with Gear Case during sub assembly with engine block at station - 5 observed by Assembly associate occuring randomly leading to the loss of 52 trators

"LH and RH"R11 fouling area. Correction done in pattern & also machinig cut added on the castings.
Zero Defect

TARGET

Revised Phenomenon

ACT
1) Reciever Gauge added in calibration plan. 2) Pattern Life Defined and Monitored.

CHECK

NOT APPLICABLE TO EEM/EPM APPLICABLE TO EEM


APPLICABLE TO EPM

Tools used:

4M 5S Starting Date:
1 Dec 2011

5W1H 5why

AM Tag ABC Class. Implementation team:

FMEA Kanban Completion Date:

NVAA OPL Costs:

Poka Yoke QA matrix Benefits

QM Matrix Six Sigma Results:

SMED VSM Benefit/Cost

X Matrix Others Verification:

Project leader
Mahender Pathak

Yogesh Kumar, Rambir Kadian

1-Feb-12

4264

66440

62,176

15::1

Ok

Why Why Analysis


Why -1 Why - 2
Cavity not ok Water pump Support Fouling with Gear Case Outer radius profile Not Ok No Inspection for Casting profile

Why - 3
Multi Cavity Variation

No Reciever gauge

Not Requir

Water pump Support Fouling with Gear Case

Analysis
Why - 4 Why - 5
No validation for Fitment during multi Cavity usage

Pattern not Ok

Not Required for Casting Profile