Six Sigma BB Project

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Six Sigma BB Project

Project Number : 01
Project Description
Bore Diameter 35 mm Unclean
in Throttle Body AC-35.

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 DOE Project Description

Phases Compl.
Date
Project reference: 001/04 -05
Phase-1 20-07-04
Date of Start : 20/07/04
Phase-2 22-07-04
Phase-3 03-08-04
Phase-4 10-08-04

Name of BB - Mr. Arvind Gupta (ACMA-ACT)

Team members - Mr. N.Prakash, Mr.I.P. Batra (UCAL
Fuel Systems Limited,Gurgaon)
Annual Cost Of Poor Quality: Rs, 1,78,610/-

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 DOE Project
Cost of Poor Quality Breakup
Rework Cost : NIL
Machining Cost : Rs 56,448/-
Raw Material Cost : Rs.1,22,162/-
Intangible Savings
1. Internal Customer Satisfaction.
2. Smooth flow of products.
3. Learning of Systematic Approach to solve the problem.
4. Breakthrough in the company towards the attitude.
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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –1- Definition

• Problem definition - Bore Unclean-

(reduced from 0.56 % to ZERO.)
• Response definition - Attribute
• Instrument to be used - Visual
• R&R study details - Not Required
• Potential SSV’s from
FMEA’s\ Brain storming – Brain storming

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase-1- Definition
Problem & Response Definition

•Problem Statement
- Bore diameter 35 mm unclean in Throttle Body AC-35.
•Response to be measured
- Bore Unclean ( Attribute)
•Specification
- No Unclean
•Instrument used to verify the Response
- Visual
•Least Count of the instrument
- Not Applicable

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –1 – Definition
R&R study details

• Is R&R study required for the Measurement

system - No
• Result of R&R study
• % E.V. - Not Applicable
• % A.V. - Not Applicable
• %R&R - Not Applicable

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –1 – Definition
Listing Potential Source of Variation

Y = f (X)
Where Y= Response ( Unclean in Bore)
X = Suspected Source of Variation (SSV)

SSVs are:
1. Mounting Hole Dia. 6.5 +0.2/+0
2. Mounting Hole Position w.r.t. Bore (X axis) 24 +/- 0.05
3. Mounting Hole Position w.r.t. Bore (Y axis) 28 +/- 0.05
4. Mounting Face Flatness 0.05 Max
5. Step in Bore Diameter 35 at Casting Stage .

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –1 – Definition
Drawing/Photograph

Locating Holes
Dia 6.5+0.2/0.0
Throttle Body
Mounting Face
0.05 max.

24 +/- 0.05
Ø 35 Bore
Unclean
28 +/-0.05 9
ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –1 – Definition
Drawing/Photograph
Sensor Bracket

Throttle Valve

Throttle Body

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –1 – Definition
Drawing/Photograph
Locating Pins Clamp

ACMA Fixture Boring Bar ACT

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Shainin DOE, Version: 1.1,Jan03
 Phase –2 – Measure and Analyze

Shainin DOE Tool selection - Paired Comparison

Data collection - Yes
Analysis of Data - Yes
Conclusion based on data - Yes

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase–2 Measure and Analyze
Tool selection

Initial Tool selected

Since the SSVs- Mounting Holes Diameter 6.5 mm

, Hole Positions w.r.t Bore center ( x & y co-
ordinates) 24 & 28 mm and Mounting Face Flatness
can be checked on Good & Bad Parts both , D.O.E.
Tool selected was Paired Comparison.

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –2 – Measure and Analyze

Data Collection
• Good and Bad parts selected based on the Response( Bore
unclean)

• 8 Best of Best (Good) and 8 Worst of Worst (Bad) parts

selected based on the Response.

• SSV’s – Dimension 28+/- 0.05 , 24 +/-0.05 , Hole Size 6.5 +0.2/-0 &
Flatness of mounting face 0.05 max. measured on both Good and
Bad parts and analyzed for the counts.
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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –2 – Measure and Analyze
Data Collection and analysis
S.N. Dimn 28+/-0.05 Result Hole - S.N. Dimn 28+/-0.05 Result
1
1 27.95 G 1 27.93 B
2 27.95 G Hole -
2 27.94 B
3 27.96 G 2 3 27.96 G
4 27.96 G 4 27.97 G
5 27.96 G 5 27.98 B
6 27.96 B 6 27.99 B
7 27.97 G 7 28.00 B
8 27.97 B 8 28.00 B
9 27.97 B 9 28.01 B
10 27.97 G 10 28.03 G
11 28.03 B 11 28.04 G
12 28.03 B 12 28.05 B
13 28.04 B 13 28.05 G
14 28.05 B 14 28.06 G
15 28.06 B 15 28.06 G
16 28.06 G 16 28.06 G

COUNT = ZERO Not A COUNT = 5.5 Not A

Cause Cause
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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –2 – Measure and Analyze
Data Collection and analysis

S.N. Dimn 24+/-0.05 Result S.N. Dimn 24+/-0.05 Result

1 23.94 B Hole -1 1 23.97 B Hole -2
2 23.95 B 2 23.97 B
3 23.95 B 3 23.98 B
4 23.95 G 4 23.99 B
5 23.95 B 5 24.00 B
6 23.95 B 6 24.01 B
7 23.96 B 7 24.03 B
8 23.96 B 8 24.05 B
9 23.97 G 9 24.05 G
10 23.97 G 10 24.05 G
11 23.97 G 11 24.05 G
12 23.98 B 12 24.05 G
13 23.99 G 13 24.05 G
14 24.00 G 14 24.06 G
15 24.00 G 15 24.07 G
One of
16 24.03 G Not A 16 24.07 G
the
Cause
Cause
COUNT = 5 COUNT = 10
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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –2 – Measure and Analyze
Data Collection and analysis
Hole -
DATA COLLECTION FOR SSV'S 2

Hole Dia 6.5+0.2/- Hole Dia 6.5+0.2/-

S.N. 0.0
Result Hole - S.N. 0.0
Result
1
1 6.61 B 1 6.62 B
2 6.62 B 2 6.62 B
3 6.63 B 3 6.62 B
4 6.63 B 4 6.63 B
5 6.63 B 5 6.63 B
6 6.64 B 6 6.63 B
7 6.64 B 7 6.65 B
8 6.64 B 8 6.66 B
9 6.66 G 9 6.66 G
10 6.66 G 10 6.66 G
11 6.66 G 11 6.66 G
12 6.66 G 12 6.67 G
13 6.66 G 13 6.67 G
14 6.66 G 14 6.67 G
15 6.67 G 15 6.67 G
16 6.67 G 16 6.67 G
Root
COUNT = 16 Cause COUNT = 12 Root
Cause17
ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –2 – Measure and Analyze
Data Collection and analysis
Flatness of
S.N. Mounting Face Result
0.05 Max.
1 0.020 G
2 0.020 G
3 0.025 B
4 0.025 G
5 0.025 G
6 0.026 G
7 0.028 B
8 0.028 G
9 0.030 B
10 0.035 G
11 0.035 B
12 0.038 B
13 0.040 B
14 0.042 B
15 0.045 B
16 0.050 G

COUNT = ZERO
Not A
Cause
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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –2 – Measure and Analyze
Data Collection and analysis
Analysis:
Hole Dia 6.5+0.2/-
S.N. 0.0
Result Since the count is
1 6.61 B =16, Mounting
2 6.62 B Hole size Dia 6 mm
3 6.63 B is one of the
4 6.63 B strongest
5 6.63 B cause of the
6 6.64 B problem
7 6.64 B
8 6.64 B
9 6.66 G
10 6.66 G
11 6.66 G
12 6.66 G
13 6.66 G
14 6.66 G
15 6.67 G
16 6.67 G

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –2 – Measure and Analyze
Data Collection and analysis
Conclusions:
+0.2/-
Inference from the data
Hole Dia 6.5
S.N. 0.0
Result •GOOD ---6.66 ~ 6.67 mm
1 6.61 B •BAD------6.61 ~ 6.64 mm
2 6.62 B •Drg. Spec.– 6.50~6.70mm
3 6.63 B Variation in the Process—
4 6.63 B
5 6.63 B
•6.61 ~ 6.67 = 0.06 mm(within Spec.)
6 6.64 B •Locating Pin size---6.57mm
7 6.64 B Clearance between Pin and
8 6.64 B locating hole
9 6.66 G
10 6.66 G GOOD
11 6.66 G Max.6.67-6.57=0.1mm
12 6.66 G Min.6.66-6.57=0.09mm
13 6.66 G
BAD
14 6.66 G
15 6.67 G Max.6.64-6.57=0.07mm
16 6.67 G Min 6.61-6.57= 0.04mm

COUNT = 16
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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –3 – Improvement

Conclusions ( Root Cause):

From the analysis ,it is evident that clearance between

Locating Pin & Mounting hole varying from 0.09 to 0.1
result in GOOD Product wherein clearance ranging
between 0.04 to 0.07 mm result in BAD product.

So we need to maintain the clearance between Pin &

Hole min 0.09 mm.

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –3 – Improvement

Opportunities available

Option No.1:To Change the Spec of Hole Size from present 6.5+0.2 to
6.66+0.06mm ( To maintain min clearance 0.09) which requires drill
size change & also sought approval from customer as the drawing is
customer approved. Subsequent fitment at the customer end was
also a constraint, so Option no.1 was ruled out.
Option no.2 : To modified the Pin size from present 6.57 to 6.52 to
maintain minimum clearance of 0.09 mm ( As per data for GOOD
parts).Option -2 ,Implemented.

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –3 – Improvement

After the countermeasure taken, 100 %

inspection of the parts carried out visually on
the machine for bore unclean problem.

Rejection found to be
ZERO out of total 15,000
parts made till now.

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –4 - Control

•Tool drawing Has been modified & standardized

for the locating pin size 6.57 to 6.52 mm.

•FMEA has been updated.

•Control Plan( maintenance) has been revised for

the pin change frequency.

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –4 - Control

• MATERIAL :EN 31
• HARDNESS :40~50
HRC
• QUANTITY :1 NOS
• ALL SHARP
CORNERS TO BE
CHAMFERED

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 FUNNELING BY 6 SIGMA

Bore Unclean

DOE TOOL
Paired Comparison
DOE TOOL

90
80
70
60
50 East
40 West
North
30
20
10
0
26
ACMA
1st Qtr 2nd Qtr 3rd Qtr 4th Qtr

ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –4 - Control

Variation analysis:
•Since the variation in the hole size is less than 50 % of the
tolerance , Pre-control chart has been implemented on the
machine to record the variation in the hole size due to drill worn
out at hole drilling stage.

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –4 - Control

•Scatter plot has been introduced on the machine to

record the no .of parts produced and the variation in
hole size to find out (optimize) Tool ( drill ) Life.

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –4 - Control

Horizontal Deployment
Throttle Body AC-38

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Phase –4 - Control
Although problem now seems to be easy ,but it was
difficult in the beginning to find out the root cause of the
problem as generally it is perceived that more clearance
between hole & pin will cause the problem whereas in
this case , it was a case of less clearance causing the
problem.
Learning:
To avoid the twist of the part while mounting on to the
fixture ,Min clearance between the locating pin & hole
shall be kept 0.1 mm approx( Subject to fitment and function of
the part).
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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
 Project Completed

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ACMA ACT
Shainin DOE, Version: 1.1,Jan03
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ACMA ACT
Shainin DOE, Version: 1.1,Jan03