ICOQM-11 June 28-30, 2011

Quality and Productivity Improvement of Common Rail Nozzles Using

DMAIC Methodology
Anant Patil
M. Tech. Production student from V. J. T. I. Mumbai. anantpaatil@gmail.com
Dr. D. N. Raut
Head of Production Engineering Department in V.J. T. I. Mumbai. dnraut@vjti.org.in

1. Abstract:
This paper discusses the quality and productivity improvement in a manufacturing enterprise through a case
study. The paper deals with an application of Six Sigma DMAIC (Define–Measure-Analyze-Improve-Control)
methodology in an industry which provides a framework to identify quantify and eliminate sources of variation in an
operational process to optimize the operation variables, improve and sustain performance viz. process yield with
well-executed control plans. Six Sigma improves the process performance (process yield) of the critical operational
process, leading to better utilization of resources, decreases variations & maintains consistent quality of the process
output.
DMAIC proved to be the most preferred technique for the defect identification and process optimization
through defect reduction. DMAIC has given the step by step approach to any complex problem and defragmented it
into micro levels to avoid scope creep.

Key words – DMAIC, Process yield, Six Sigma, Quality improvement.

2. Introduction:
The diesel engines have proven the best performances in this era with the start of common rail injection
system. The most functional part of the system is an electronic controller. The nozzle is the only functional part that
comes in contact with combustion chamber. Though fuel injection system is configured very well according to
specifications, the performance of the CRIS (Common Rail Injection System) deteriorates with the use of
contaminated oil and nozzles. Also during machining of nozzles in subsequent phases the burr particles are found
accumulated in the cavities of the nozzles and also on the edges of the ground surfaces. The burr should be removed
off in order to get better and smooth operation of the nozzle because the burr accumulated inside the cavities may
block the spray holes of the nozzle during operation leading to weak spray of fuel. Therefore arrangement of
cleaning of a nozzle thoroughly has been made to get better quality of nozzles. Nozzles are cleaned by series of
operations which involves demagnetization, deburring, inside cleaning and outside cleaning. At the end of the all
processes the contamination inside the nozzles is checked by a test. If the reports of the test are not satisfactory,
cleaning of the nozzles was carried out. This cycle was repeated until reports came satisfactory. Obviously causing
extra burden on the resources in terms of workers, cleaning media and testing capacity of line. This was also the
main hindrance for the ramping up of the production of extra nozzles. To solve the above problem management
came up to have an improvement project through DMAIC principals.

3. DMAIC used in the sequential stages

The DMAIC methodology stands for: Define, Measure, Analyze, Improve and Control. (Antony & Banuelas,
2002). Evaluation of current case with help of DMAIC is shown in the continuous steps as follows:-
A. Define Phase:
As said by well-known mathematician, analyst and philosopher
“The greatest challenge to any thinker is starting the problem in a way that will allow a solution.”
— Bertrand Russell
The project definition is arguably the most important part of the project life cycle, because it establishes the
basis for the other project management sub processes. To define a problem several tools are used such as project
charter, SIPOC diagram, process flow and CTQ (Critical to Quality) diagram etc.

Development of a Project Charter:

A project charter is a written document that works as an agreement between management and team about
what is expected (Fig. 1). The charter clarifies what is expected from the team, keeps the team focused, keeps the
team aligned with organizational priorities, transfers project from the champions to the project team.

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Problem statement:
The main concern of operational process was, low cleanliness first pass yield of common rail nozzles. As
contribution to contamination of nozzle is from each end of machining process, the concerned process starts with the
hardening of nozzles.

Six sigma project charter

Project : To improve yield of CR nozzles in complaience with Leica specifications & control limits.
1. Background & reasons for selecting the project :
100% recleaning of CR nozzle resulting in loss of capacity of high cost testing line.
2. Aim of the project :
1) Increase cleanliness FPY of CR nozzle test line to 95%.
2) To increase testline utilisation.
3) To support ramp-up of CR nozzle.
3. Sponsor : Mr. GM 4) Team leader :Mr. Deputy Manager

5. Team members :
1) Employee of concern
2) Planners of concern
3) Process expert from concern
4) Employee of concern
6. Characteristicks of output of product / process & its measures:
Characteristics: Measures: Defect definition:
Contamination reports bad Daily statistics of Contamination report. Refer encloser 1.
7. Source of the project : Daily data of Contamination report.
8. Benefits / Cost impact :
1) EDCC+ manpower : 1.6 MINR/ month.
2) Additional 3000 TAT nozzles per Day.
3) Savings due to stopping recleaning (Oil Consumption).
4) Additional 3000 CR nozzles per day.
9. Meeting frequency : Every Thursday at 4:00 pm to 5.00 pm.
10. Enclosers :
Daily statistics of Contamination Reports, defects defination.
Dept : 105 Page : 1 Revision : 0 Date : 23/07/2010

Fig.1. Project Charter Fig. 2. Process flow diagram

SIPOC Diagram:-
SIPOC is a high level map of a process to view how a company goes about satisfying a particular customer
requirement in the overall supply chain.
SIPOC stands for:
Its Supplier-Input- Process-Output-Customers diagram. It gives high level view of a process, helps to define
project boundaries and describes from where to collect data (fig.3). The purpose of SIPOC is to avoid scope creep
and to highlight areas of improvement to ensure focus on customer.
Process Deliverables:
1. Reduction of rework required to clean contaminated nozzles.
2. Reduction in the wastage of production test line’s capacity.
3. Reduction in COPQ
4. Increased cleanliness First Pass Yield of CR nozzles.
Customers:
Internal customers:
1. Internal injector customer
2. Quality over checker
External Customers:
1. Clients
2. Third party inspectors.
3. Customer representatives.

Defining Process Boundaries and Customer CTQ requirements:

Process Boundaries - Process Start Point: - Internal guide bore grinding operation
Process Stop Point: - Visual over nozzle ready for contamination testing
Purpose of CTQ diagram is to translate customer or business requirements into specific critical to quality
(CTQ) requirements. CTQ diagram also helps the team to move from high level needs to very specific measurable
customer or business parameters.

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Fig.3. SIPOC diagram

Customer CTQ Requirements:

The customer data (VOC) revealed that internal customers are mainly affected by higher contamination level
in the Common Rail Nozzles. CTQ characteristics are established and a CTQ tree (Fig. 4.) is prepared on the basis
of the VOC and project objective.
CTQ

NEED DRIVER Count of particles having size

To decrease Contamination 1. >200µ = 0

contamination level of Calibration Test 2. 150 - 200µ = 3
common rail nozzles. 3. 100 - 150µ < 10
4. 50 - 100µ < 70
5. 25 - 50µ <100
Fig.4. CTQ diagram for the problem

B. Measure Phase:
When you can measure what you are speaking of and express it in numbers, you know that on which you are
discoursing. But if you cannot measure it and express it in numbers, your knowledge is of a meagre and
unsatisfactory kind.
— Lord Kelvin
Approach to measure phase is as follows:-
Collect Validation of
baseline data Develop measurement Analysis Determine
on defects & Sampling system using pattern of process
possible Strategy GRR data capability
causes

This phase presents the detailed process mapping, operational definition, data collection chart, and evaluation of the
existing system and assessment of the current level of process performance.
Process Mapping:-
The process map of the Common Rail nozzle production process under consideration is prepared by
practically studying the process and then mapping various sub-activities in it (fig.2). Mapping helped to visualize
and separate value-added activities from non value added activities and to isolate the hidden waste streams.
Operational Definition:-
To calculate current level of process performance the total record of Contamination reports for a month is
taken and ratio of count of a range coming correct with the total reports under consideration is calculated. For the
month of August rejection was very high almost 100% thus rework to clean a contaminated nozzle was a routine
practice. As measurement is purely done by an automated system and there was no manual intervention, GRR was
not needed and only a gage calibration study was carried out.

C. Analyze Phase:

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Many defects arise because something in a process is done incorrectly and inefficiently. To improve process
sigma, it is necessary to pin point process problems and find more effective ways to accomplish the same work.
Thus a detailed map of process is prepared to identify value aided and non-value aided activities.

Fig.5. Root-Cause analysis done for high contamination in common rail nozzle

FMEA:-
Potential Failure Mode and Effect Analysis (Process)
Part/Item : Responsibility : FMEA No.
Process: Carrying out SS project Key date: FMEA date (Org.):

Process Potential Potential Potential Cause(s)/ Current Process Recommended Responsibility Action Taken Action Results
Function / Failure effect of Mechanism(s) of failure Controls action(s) and Target
OCC

RPN

OCC
SEV

RPN
DET

SEV

DET
requirmrnts mode Failure Completion
date
Contamination High increased in 10 needle burr generated on 9 no control 6 540 1. Machine setting as Cross hatch setting
in the common contaminat no. particles surface grinding per Bap 2.Wheel as per BaP
rail nozzles ion of size more configuration as per
should be resulting than 50µ BaP 9 1 4 36
incomplience into Deburring jets worn out and 7 use of alumina 5 210 Define behavior of jet Machine will give
with Leica Test reclining of not replaced resulting into nozzles to see wear and incorporate warning of impact
nozzles improper impact on edges severiry of impact changes in machine checking after every
leading to no burr removal on nozzle surface software month
after every month 9 1 1 9
Hitting of the nozzle body 7 no control 6 252 1. Use ceramic loader, Changed loading
counter bore edge on loader 2.Changeloading angle from 45⁰ to
resulting into sticky angle, 3. Learn statt to 60⁰
assembly operators 9 2 2 36
Brushing inside nozzles is 8 no control 7 336 1. Increase brush 1.Established new
ineffective on internal length 2.Increase inside brushing
grinding operation resulting brushing strokes station with
into the no deburring of 3.Brush Rotation clockwise and
pressure chamber edge counterclockwise
rotation of brushes
9 2 7 126
Flushing was not carried out 10 no control 8 480 Establish optimum flushing after type
frequently resulting into flushing plan change from DSLA
overall increase in to CR and in night
contamination level of the shifts
cleaning media 9 1 1 9

Fig.6. FMEA for contamination inside the nozzles is violating the limits set by test

In the analysis phase team brainstorms on X’s (potential causes) the vital X’s (Root causes) which when
improved will show impact on Y (CTQ’s). Root Cause analysis (fig.5), FMEA analysis (fig.6), why-Why analysis,
which leaded to identify the critical few factors in order to identify the ‘Root causes’ for the process incapability.

D. Improvement Phase:
In the improve phase team works on the root causes and takes some improvement measures so that control is
established.

1. Hitting marks while loading in the EDM machines (EDM):-

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During spray hole machining on an EDM machines the mandrel of the machine was hitting the nozzles at the
entry of the guide bore. The defect was first identified on the pairing bench, when a well shaped needle is not getting
assembled in the nozzle body. The bodies having hitting marks at the entry of the guide bore are defective and
offering resistance for a needle to go inside the guide bore. As the hitting marks were not visible by naked eyes it is
assumed that burr might have encountered between needle and body. The actual problem came to focus after
realizing that the resistance offered was at edge of counter bore only and not over all the guide surface. The detailed
investigation revealed that due to hitting marks, the dent formation had taken place at the entry of the guide bore.

Fig.7. Location of defect in a nozzle Fig.8. Dent mark or hitting marks

When a defective body (body with hitting mark on the entry edge of guide bore) was assembled with a
needle, needle remained stuck inside the guide bore. When a needle was pushed inside the guide bore with little
more force than shaking of tray, dents got fractured forming a burr accumulated inside a nozzle. Thus finally metal
particles were entering inside the nozzle. It was also observed that after few up and downs movements of the needle
inside nozzle body; body and needle became freely moving suggesting complete wearing of dent.
Samples of sticky nozzles were collected and contamination was calculated, which gave us following
statistical report of burr content after repair of nozzles:-

Sample No. Cheek Sheet grade 50 – 100 µ 100 – 150 µ 150 – 200 µ > 200 µ
1. Sevier 144 102 72 66
2. moderate 37 38 45 40
3. repairable 30 20 25 12
4. Soft damages 15 10 9 3
5. Only single pressing 8 5 3 4

Root cause of sticky nozzles:-

We analyzed the detailed process of a nozzle body after hardening and found three possible cases of defect:-
1. Hitting of a mandrel on an External grinding machine.
2. Hitting of a mandrel on a Chamfer grinding machine.
3. Hitting of a mandrel on an EDM machine.
Analysis of phenomenon of dent marks formation on each and every machine was done and we observed
following facts-
a) On the EDM machines some of the nozzles were sticky after operation.
b) After carrying out loading for validation it is observed that purposefully created marks and hitting marks
on the sticky nozzles were exactly matching.
c) The direction of loading of the operator and the mandrel inclination were slightly intersecting each other
causing hitting of the nozzles on the mandrels (Fig. 10).
d) The mandrels of the EDM machine are hard, having three acute edges formed due to relief given on the top
side for functional requirement (fig. 9) which is more susceptible to create damages.

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10 - 20º

Fig.9.Tip of AGIE mandrel Fig. 10.Clashing condition or hitting condition

The problem of hitting of the nozzles on the mandrels was rectified by changing the initial inclination angle
of the mandrel from 45º to 60º (fig.11). Learn stat given to the operators about the loading error and its solution.
Both resulted in less rejection as well as lesser severity of damage as compared to earlier operation.

Coincidence of
loading axis with
mandrel

60®

Fig.11.Modified position - 60º inclination of mandrel

2. Needle burr generated after surface grinding operation:-

After pairing, nozzles are finally delivered at top face grinding operation. The operation is called as very
critical operation because parameters such as flatness, surface finish, Rz value of ground nozzle are checked for each
setting on top face grinding machine. Fully ground nozzles are given over a deburring machine wherein at deburring
station burr removal at the edges of the dowell holes, inlet hole and counter bore is carried out.

Fig.12. IH – DH burr Fig.13. Needle burr

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Date Needle Inlet hole Counter bore dowell

21/1 60 13 2 10
22/1 47 22 1 6
23/1 53 20 2 13
24/1 70 13 2 5
28/1 63 9 4 4

Fig.14. Check Sheet & Bar chart of burr content visible under scope on a nozzle.

Deburring station has only provision of burr removal at the entry edges of dowell holes, inlet hole and counter
bore. SEM reports show us that Needle burr (fig. 13) had major contribution in the contamination of the nozzles.
Deburring had no provision for the burr removal on the needle. After deburring machine analysis of the nozzles for
burr at the edges of the holes was done and it is observed that deburring mechanism is ineffective to remove burr.
Thus immediately impact of the jets on the aluminum nozzle was observed and decided to replace all deburring tips.
Similarly check sheets (Fig. 14 & Fig. 15) for burr observed on nozzles before tips change and after tips change was
prepared to see changes; burr present on the edges of the counter bore, dowell hole and inlet hole was completely
removed after jets change.

Date Needle Inlet hole Counter dowell 80

burr burr bore hole 70
29/1 50 4 2 0 60
dh
50
cb
30/1 55 7 0 5 40
ih
30
01/02 56 3 1 2 needle
20
10
02/02 68 4 2 1 0
29 30 1 2 4
04/02 87 2 0 0

Fig.15.Bar chart showing burr observed on the nozzle after deburring jets replacements

To maintain concavity on the top surface of the nozzle, grinding wheel is inclined with respect to nozzle axes.
Due this inclined setting it was possible to remove burr from only one side of the nozzle (Fig. 15). In the above
setting large amount of burr depositions formed on the inside edges of the inlet hole and dowell holes, also specific
grinding surface was very less. The main concern was the needle burr, there was no procedure to remove it
mechanically .Because of partial distribution of the cut at the grinding region as well as wheel velocity and needle
velocity were unidirectional leading to less effective grinding at the needle top. The other setting was carried out in
which the nozzle and wheel axes were completely paralleled .The depth of cut per revolution (or per sec.) of the
nozzle in this setting is lesser compared to inclined setting of a wheel, also material is removed uniformly from two
contacting faces whereas needle surface is acting as a pivot (Fig. 16.)
In cross hatch setting very less amount of burr is generated on the body while no burr was observed on the
boundaries of the needle top face. Most of the burr was carried away by the wheel and absolutely no deposition of
hard burr particles on needle is observed.

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Current Condition Better Condition

Fig.16.Setting for concavity (Inclined wheel) Fig.17. Setting for cross hatch (Wheel and Nozzle
axes paralleled)

Date Needle Inlet hole Counter dowell

burr burr bore hole 8
7
10/02 2 0 0 1
6 dh
11/02 1 3 1 0 5
cb
4
ih
12/02 2 0 0 1 3
2 needle
13/02 2 2 3 0 1
0
14/02 3 2 0 1 10th 11th 12th 13th 14th

Fig.18. Check Sheet & Bar chart for getting needle burr after cross hatch setting.

3. Flushing was not carried out in between shifts and after type change:-
Flushing is an activity of cleaning test oil on a test line with help of a separate circuit by passing the oil
through series of filters. All test oil after deburring operation is collected in a bottom tank and is circulated to a main
tank with help of a pump. Test oil after coming out of deburring jets removes burr sticking to the inside edges of the
inlet hole, dowell hole, edges of the counter bore and from the cavity of the nozzle bodies. The oil after cleaning is
collected in the bottom tank and is fed to a main tank when threshold level is reached.
During production run all contaminated oil is collected inside bottom tank was not frequently circulated
through the series of two bag filters and a bar filter. Therefore overall contamination level of the oil was increasing
as there were very less passes of the oil through the filters. The trend of not flushing after shift changes and after
type changing was happening regularly because of which the overall contamination level of the oil got increased.
Validation was done by passing clean dummy nozzles over the test line when flushing is not done as usual.
All contamination reports of dummy nozzles gave us addition of microscopic burr. The burr observed under scope
was similar to burr found at deburring station. Therefore, one hour flushing of machine was made mandatory after
shift and type change.
Contamination statistics for validation of flushing:

Before Flushing (Dummy Nozzles) After Flushing (Dummy Nozzles)

50-100µ 100-150µ 150-200µ >200µ 50-100µ 100-150µ 150-200µ >200µ
10 0 0 0 20 5 0 3
20 0 0 0 10 3 2 0
8 0 0 0 25 1 1 1

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Addition of burr particles of size more than 100µ shows that oil is contaminated and not properly cleaned.
Although filters have been changed periodically overall cleanliness of oil is not achieved, thus oil needs to be passed
through filters continuously for a stipulated period to achieve better cleaning of test oil.

4. Deburring jets worn out and ineffective:

Fig.19. Deburring in action Fig.20. Impact area on the nozzle

At deburring station, jets of oil impeaching from a special carbide tips make impact on the edges of the inlet
hole, dowell hole and the edges counter bore (Fig. 20) with the use of test oil pumped up to pressure of 350 bar by a
powerful reciprocating pump (Fig. 19). Due to impact, burr is getting dismantled from the edges and is carried out
with oil in the bottom tank. After every two months, impact of deburring jets is checked on the aluminium nozzles.
The impact is made by carrying out deburring for 5 min and recesses on the nozzle are analyzed. After analysis,
impact was improper with lesser intensity. The distance of each impact from the center of aluminum nozzle is
calculated and compared with the required values. In the earlier cases tips were not replaced timely causing over
sizing of the carbide tips giving lesser impact on the edges of nozzles. Also one of the tip found irregularly eroded
causing impact on the nozzle holder. After replacement of tips, burr removal phenomenon was improved, three
successful batches found with no burr on the edges of counter bore, inlet hole and dowell hole.

5. Pressure chamber burr produced during internal grinding operation:

During guide bore grinding operation, burr was produced at the inside edges of the guide bore towards
pressure chamber (Fig. 21). The burr was half way connected to the guide bore (Fig.22) Burr removal was difficult
because of restricted passage of guide bore. To detect burr a boroscope was needed.

Fig.21. Pressure chamber burr location Fig.22. Boroscope view of burr

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A brushing station having facility of brushing in clockwise and anticlockwise direction of a brush rotation
was implemented. In earlier case brushing was taking place inside the internal grinding machine but it was
ineffective because of improper brushing length and depth of brushing stroke. With new dedicated brushing machine
trend of burr removal was improved. Defined a brush life of 300 pieces.
After implementing all the improvement measures a marginal increase in the cleanliness of the common rail
nozzle was observed as shown in the chart (Fig.23) given below. The first pass yield is improved up to 97%.

120
100
80
60 FPY
40
20
0
45

47

49

51

11

13

15

17

19
cw

cw

cw

cw

Fig.23.Chart showing the First Pass Yield improvement of common rail nozzles

E. Control Phase:
After successful implementation of the improvements it is needed to document the changes made in the
process. Following control measures were taken to control vital X’s so that there will not be repetition of the
scenario
1. To control the defectives produced during EDM operation the initial inclination angle of mandrels are
changed to 60°. The changes are recorded into instruction charts and learn stat was given to the operators.
The awareness about the defect was focused in the training sessions. Only experienced operators are
allowed to work on EDM machines.
2. An automatic signaling program is incorporated in the machine for impact checking of the deburring jets.
The machine was made susceptible to give warning of jets replacement on the safety period of one week.
Also training to the operators about jet changing and impact calibration was given.
3. On the top face surface grinding machine setting procedure of the wheel is defined and given to operators.
Changes in the instruction chart are made.
4. After internal grinding burr removal was carried out with help of a double brushing station, the brush life
of 200 pieces was established. An automated signal for the brush change will be generated on the machine
for brush replacement.
5. Flushing is kept mandatory after night shift as well as after type change from less sensitive type to the most
sensitive so as to clean thoroughly the cleaning media.

4. Conclusion:-
As the cleanliness of the nozzle was the critical quality issue the step by step application of the tools and
focused study helped to solve the business case. Step by step approach of the DMAIC methodology helped to realize
the problem. The improvements gave the cleanliness first pass yield of the nozzles up to 95% from the initial value
of 0%. Due to increase in the quality level of the product internal customer is satisfied and increased demand of
nozzles is fulfilled. As the test line is remained open for the more production and also the rework was completely
stopped the overall productive efficiency is increased. The wastage due to more use of cleaning media is completely
stopped as it has given a threefold success to the organization.

5. References:-

Books:
1. World Class Applications of Six Sigma – Real world examples of success edited by Jiju Antony, Ricardo
Banuelas and Ashok Kumar.
2. Implementing Six Sigma and Lean – A practical guide to tools and techniques by Ron Basu.
3. Lean Six Sigma For Service: How to Use Lean Speed and Six Sigma Quality to Improve Services and
Transactions by Michael L. George ISBN: 0071418210 McGraw-Hill © 2003.

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4. Implementing Six Sigma – Smarter Solutions Using Statistical methods by Forrest W. Breyfogle III
5. Introduction to Engineering Statistics and Six Sigma Statistical Quality Control and Design of Experiments and
Systems by Allen, Theodore T.
6. Six Sigma- Advanced Tools for Black Belts and Master Black Belts by Loon Ching Tang(National University of
Singapore, Singapore), Thong Ngee Goh (National University of Singapore, Singapore), Hong See Yam
(Seagate Technology International, Singapore), Timothy Yoap (Flextronics International, Singapore).

Research works:
1. Six Sigma – A New Direction to Quality and Productivity Management by Tushar N. Desai and Dr. R. L.
Shrivastava
2. Sigma system: Concepts and structure by Noboru Akima, Shuji Nakata , Akiyoshi Nishijimab, Tetsuya Kubo
and Yasuo Konishi.
3. Integrating the global enterprise using Six Sigma: Business process reengineering at General Electric Wind
Energy by Sanjay Goela, Vicki Chenb.
4. A systematic methodology for the creation of Six Sigma projects: A case study of semiconductor foundry by
Chao-Ton Su, Chia-Jen Cho
5. Six Sigma: Definition and underlying theory by Roger G. Schroeder , Kevin Linderman , Charles Liedtke ,
Adrian S. Choo.

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