Project:2

Helmet Lock Assy. Not working

Slide Number: 1

22ND MAR2004

Project - Helmet Lock Assy. Not Working

Project reference:SLD-I / Assy line Date of Start:01/02/2004
Phases Phase-1 Phase-2 Phase-3 Phase-4 Compl. Date 01.02.04 27.02.04 06.03.04 13.03.04

Team leader: VIKAS SETHI Team members: K.K.S ,P.C., R.S.D., N.M., V.T.
Annual Cost of Poor quality: Rs. 4.5 L (Year: Apr 2003 Mar 2004)
Slide Number: 2

22ND MAR2004

Project - Helmet Lock Assy. Not Working Cost of Poor Quality Breakup Rework cost = Rs 2.50 / pc Processing cost = NIL Material cost = Rs 20 / pc Intangible Savings Customer Satisfaction Smooth assembly line flow
Slide Number: 3

22ND MAR2004

Phase 1- Definition
Problem definition Response definition Instruments to be used R&R study details Potential sources of variation from FMEA s/Brain storming
Slide Number: 4

22ND MAR2004

 Problem Statement

Phase 1 Definition Problem and Response definition

Helmet lock assy. not getting locked after a push load is applied on cap button during locking.

Response to be measured
Lock Operation (Attribute )

Specification
Assy. should get locked when load is applied on cap button

Instrument used to verify the Response

Visual
Slide Number: 5

22ND MAR2004

Phase 1 Definition R&R study details

Is R&R study required for the Measurement system
NO

Slide Number: 6

22ND MAR2004

Pictorial view of Helmet Lock assy.

SPRING SHUTTER SHAFT COVER INNER CYLINDER CAP INNER COVER CAP INNER T.DISC& COMP. SPG.

BODY BAR SLIDER SLIDER SPRING RETURN SPRING SLIDER PLATE BACK
ND MAR2004 CAP 22BUTTON

Slide Number: 7

PRODUCT IN WHICH PROBLEM IS OBSERVED

Cap button
Slide Number: 8

22ND MAR2004

Component Helmet Lock Body Slider Plate Back

Phase 1 Definition Potential sources of Variation

Parameter Dim 20-0.1 , 12.5-0.05 thickness 1.5-0.1 ,DIM 9 +0.1 flatness Dim12.75 0.1 flatness, thickness 1.0 0.05 dim 6 0.1 ,3.5 0.1 12.45-0.05 ,dim 19.7-0.1 leg height 2 -0.1, dim 6.6-0.1 0.05 & 0.1 In-house 22 Slide Number: 9

Inner cylinder Bar Slider Assembly Process

ND

MAR2004

Phase 2 Measure and Analyze

Shainin DOE tool selection Data collection Analysis of Data Conclusion based on data Validation of the Cause before going for Improvement
Slide Number: 10

22ND MAR2004

Phase 2 Measure and Analyze Tool selection

Modified Component search method Initial tool selected Since assembly is a suspected source of variation and the assembly can be disassembled and re-assembled after damaging some of the components at functional area, hence Modified Component Search was selected as tool for investigation
Slide Number: 11

22ND MAR2004

Phase 2 Measure and Analyze Collection of Data using C. Search

One Good assembly and One Bad assembly were selected for Modified Component search Response is attribute Body helmet lock is getting damaged during swapping
Good Initial value First disassembly & reassembly Second disassembly& re-assly Good Good Good Bad Bad Bad Bad

Since Good remains Good & Bad remains Bad , it was concluded that Assembly & Body Helmet Lock are not the cause of Problem, the other components used in assy are the cause of problem. 22 MAR2004
Slide Number: 12
ND

Phase 2 Measure and Analyze Collection of Data using C. Search

The following components were selected based on experience for interchange in the same order ;
A - plate back interchanged. B - slider interchanged. plate back + slider interchanged C Bar Slider interchanged D - Inner Cylinder interchanged.

Components were interchanged in the same order to see the change in the Response. 22 MAR2004
Slide Number: 13
ND

Phase 2 Measure and Analyze Collection of Data using C. Search

Category A+RB+RA+B+RC+RD+RGood Good Good Good Good Bad Category A- R + B- R + A- B- R+ C- R + D- R + Bad Bad Bad Bad Bad Good
22ND MAR2004

Slide Number: 14

Phase 2 Measure and Analyze Collection of Data using C. Search Since the parts were interchanged the result was:
Good remained good & bad remained bad on interchange of Plate Back Good remained good & bad remained bad on interchange of Slider Good remained good & bad remained bad on interchange of Plate back + Slider Good remained good & bad remained bad on interchange of Bar Slider. Good turned bad & bad turned good on interchange of Inner Cylinder This proves that all the components are ok, the only the inner cylinder is causing the problem .
Slide Number: 15

22ND MAR2004

Funneling
Assy , body
Y( Lock operation)=f( x- assy. ,body plate back , slider, I/C, Bar slider )

Modified Component search

Inner cylinder

Y( Lock operation)=f( x- Inner Cyl )

Slide Number: 16

22ND MAR2004

Phase 2 Measure and Analyze tool selection

Paired Comparison
Further tool selection for investigation
Now since the assy & all other components are ruled out & we have come down to Inner cyl. as the cause hence it has to be investigated for further cause identification. To do this, Paired comparison was selected as tool

Suspected dimensions in Inner Cylinder are

12.45(- 0.05 ) dim 19.7 ( - 0.1 ) leg height 2 ( - 0.1 ),
Slide Number: 17

22ND MAR2004

Phase 2 Measure and Analyze tool selection

The data collected for the Inner Cylinder and analyzed based on paired comparison , shown in the next slide Six Worst of worst assemblies and Six Best of Best assemblies were taken. Since the count for dim( 19.7-0.1 + 2.1-0.1 ) is 12 hence we can conclude that it is causing the problem.
Slide Number: 18

22ND MAR2004

broken / not broken B B B B B B G G G G G G

S. No. 35 44 12 2 26 95 49 19 5 58 65 72

Dia 12.45 12.41 12.44 12.44 12.44 12.43 12.4 12.42 12.42 12.43 12.45 12.43 12.42

Dim 6.6 6.5 6.59 6.52 6.54 6.56 6.56 6.51 6.54 6.58 6.56 6.6 6.57

Dim 19.7 19.6 19.65 19.66 19.63 19.65 19.68 19.7 19.8 19.85 19.72 19.74 19.76

Dim 2.1 2 2.05 1.95 2.04 1.98 1.96 2.1 2.1 2.1 2.12 2.12 2.1

21.80 21.60 21.70 21.61 21.67 21.63 21.64 21.80 21.90 21.95 21.84 21.86 21.86

Phase 2 Measure and Analyze Collection of Data & analysis Dia 12.45
12.40( B ) 12.41 ( B ) 12.42(G) 12.42(G) 12.42(G) 12.43(B) 12.43(G) 12.43(G) 12.44 ( B ) 12.44(B) 12.44(B) 12.45(G)

COUNT = 3
Slide Number: 20

22ND MAR2004

12.45

Phase 2 Measure and Analyze Collection of Data & analysis Dim 6.6
6.5 ( B ) 6.51 ( G ) 6.52 ( B ) 6.54 ( B ) 6.54 ( G ) 6.56 ( B ) 6.56 ( B ) 6.56 ( G ) 6.57 ( G ) 6.58 ( G ) 6.59 ( B ) 6.6 ( G ) 6.6

COUNT = 2
Slide Number: 21

22ND MAR2004

Phase 2 Measure and Analyze Collection of Data & analysis

Dim 19.7 19.6 ( B ) 19.63 ( B ) 19.65 ( B ) 19.65 ( B ) 19.66 ( B ) 19.68 ( B ) 19.7 ( G ) 19.72( G ) 19.74 ( G ) 19.76 ( G) 19.8 ( G ) 19.85 ( G ) Dim 2.1 1.95 ( B ) 1.96 ( B ) 1.98 ( B ) 2(B) 2.04 ( B ) 2.05 ( B ) 2.1 ( G ) 2.1 ( G ) 2.1 ( G ) 2.1 ( G ) 2.12 ( G ) 2.12 ( G )
Slide Number: 22

21.80 21.6 ( B ) 21.61 ( B ) 21.63 ( B ) 21.64 ( B ) 21.67 ( B ) 21.7 ( B ) 21.8 ( G ) 21.84 ( G ) 21.86 ( G ) 21.86 ( G) 21.9 ( G ) 21.95 ( G)
22ND MAR2004

Funneling
Assy , body
Y( Lock operation)=f( x- assy. ,body plate back , slider, I/C, Bar slider )

Plate, slider, bar

Modified Component search Paired comparison

Inner cylinder

Y( Lock operation)=f( x- Inner Cyl )

Dim 19.7 + 2.1

Y( Lock operation)=f( x- I/C dim )

Slide Number: 23

22ND MAR2004

Phase 2 Measure and Analyze Conclusions

Inner cylinder Dimensions 19.7-0.1 + 2.1-0.1 are creating the problem. These dimensions are given separately in drawing. These dimensions can be merged as one dimension, it can vary from 21.8 ~ 21.95 mm
Slide Number: 24

22ND MAR2004

ROOT CAUSE
19.7-0.1 2.1-0.1

Slide Number: 25

22ND MAR2004

 B VS C DONE. Assumption : the dim 19.7 & 2.1 will lead to distinct separation between good & bad 3 Bs Selected Dim 21.95 3 Cs Selected Dim 21.6 C B Bad Bad Bad Good Good Good
Slide Number: 26

Phase 2 Measure and Analyze VALIDATION

22ND MAR2004

Funneling
Assy , body
Plate, slider, bar
Y( Lock operation)=f( x- assy. ,body plate back , slider, I/C, Bar slider )

Modified Component search Paired comparison

Inner cylinder

Y( Lock operation)=f( x- Inner Cyl )

Dim 19.7 + 2.1

Y( Lock operation)=f( x- I/C dim )

B V/S C
Slide Number: 27

22ND MAR2004

Phase 3 Improvement
Inner Cylinder dimensions revised in drawing. Identification of Interim & Permanent actions to correct the cause identified in Phase 2 Implementation of the actions
Slide Number: 28

22ND MAR2004

Phase 3 Improvement
Lot segregation done & 45 pcs. Rejected / 4000 pcs. O.K pcs Fed on line & found locking operation O.K. 22580 pcs. made till 9/3/04 with modified die pieces are found to be O.K.
Slide Number: 29

22ND MAR2004

Phase 3 Improvement
Horizontal Deployment
All the above actions are planned for other varieties of Inner cylinder.
Slide Number: 30

22ND MAR2004

Phase 4 - Control
Implemented controls to make sure that the actions taken in Phase-3 are done for ever Updation of FMEA and Control Plans based on the analysis done in Phase-2
Slide Number: 31

22ND MAR2004

Phase 4 - Control
Die modified as per the drawing . Supplier to maintain the dim & send inspection report for in process inspection/ dock audit . In process inspector will monitor the dimension, & give the feed back to DOE team on daily basis to highlight the dimensional variation, if any.
Slide Number: 32

22ND MAR2004