Process Capability Analysis of all Machining Operations of

Piston Production lines in Piston Machine Shop

PROJECT MEMBERS

 Muhammad Ali
 Muhammad Zeeshan Nazir
 Muhammad Abdullah Fazal
 Mohammad Ahmed

Project Supervisor: Engr Attaa Ahmed Malik

Project Advisor: Engr Syed Ahmed Jawa

1
 Acknowledgement

The internship opportunity we had with Atlas Engineering was a great chance for learning and professional
development. Therefore, we consider ourselves as fortunate individuals as we were provided with an
opportunity to be a part of it. We are also grateful for having a chance to meet so many wonderful people
and professionals who led me though this internship period I express my deepest thanks first to Allah
Almighty then to Mr. Ataa Ahmed (Assistant Manager Piston Machine shop) for taking part in useful
decision & giving necessary advices and guidance and arranged all facilities to make it possible. I choose
this moment to acknowledge his contribution gratefully. It is my radiant sentiment to place on record my
best regards to Mr. Syed Ahmed Jawad (Manager Machining), Mr. Wahaj (Supervisor Production lines) and
Miss. Natasha (Executive HR) for their careful and precious guidance which were extremely valuable for our
study both theoretically and practically. We perceive this opportunity as a big milestone in career
development. We will strive to use gained skills and knowledge in the best possible way, and will continue
to work on their improvement, in order to attain desired career objectives. Hope to continue cooperation
with all of you in the future.

2
 TABLE OF CONTENTS
INTRODUCTION ............................................................................................................................................................ 4
Problem Statement .................................................................................................................................................. 4
Atlas Engineering – Piston Production Plant ................................................................................................... 4
LITERATURE REVIEW ................................................................................................................................................ 5
Process Capability: ................................................................................................................................................. 5
Cp and Cpk: ............................................................................................................................................................... 5
Specification.............................................................................................................................................................. 5
Standard Deviation .................................................................................................................................................. 5
Mean ............................................................................................................................................................................ 5
Cp ................................................................................................................................................................................. 5
CpK .............................................................................................................................................................................. 5
Cp Acceptable Range: ............................................................................................................................................ 6
DATA ANALYSIS AND CALCULATIONS ................................................................................................................ 6
Data Collection ......................................................................................................................................................... 6
Production Lines:................................................................................................................................................. 6
Operations: ............................................................................................................................................................ 6
Dimensions (USL, LSL) .......................................................................................................................................... 7
PRODUCTION LINE 1, GB–5 Piston ................................................................................................................ 7
PRODUCTION LINE 2, GB–5 Piston ................................................................................................................ 8
PRODUCTION LINE 3, KTA Piston................................................................................................................... 8
PRODUCTION LINE 4, KYHA Piston ............................................................................................................... 9
PRODUCTION LINE 5, CG-125 Piston ............................................................................................................. 9
PRODUCTION LINE 6, GB-5 Piston ............................................................................................................... 10
DIMENSIONS MEASURING GAUGES: .............................................................................................................. 10
PROCESS CAPABILITY CALCULATIONS: ...................................................................................................... 14
PRODUCTION LINE 1, GB-5 ............................................................................................................................ 14
PRODUCTION LINE 2, GB-5 ............................................................................................................................ 16
PRODUCTION LINE 4, KYHA Piston ............................................................................................................. 20
PRODUCTION LINE 5, CG-125 ........................................................................................................................ 22
PRODUCTION LINE 6, GB-5 Piston ............................................................................................................... 24
EVALUATION............................................................................................................................................................... 26
EVALUATION ON CP RANGE BASIS: ............................................................................................................... 26
PROBLEMS AND CAUSES CHART: .................................................................................................................. 26
CAUSES AND EFFECT DIAGRAM (FISH BONE DIAGRAM): ...................................................................... 28
CONCLUSION: ................................................................................................................................................................. 29

3
 INTRODUCTION

Atlas Engineering established back in 1951, currently under holdings of Shirazi Investment
Limited, is one of the largest and oldest automotive parts manufacturer in Pakistan’s private
sector.
One of the major aluminum parts that are manufactured by the company are four different kind of
pistons for four different models of motorbike engines for OEM sector Atlas Honda. Pistons are
one of crucial part of reciprocating engines. It is fitted in cylinder and made gas tight by using
piston rings. Main function of piston is to transfer the energy produced by combustion to
crankshaft by means of connecting rod to produce the required toque. Piston being the critical part
must be fabricated with high precision so that it meets the required standards. Hence it’s important
to track the capabilities of processes used to manufacture a piston.

The production lines in Piston machine shop contain two types of machines, CNCs and PLCs.
Some of the machines from the production lines are working for more than few decades. Thus,
their machining capability is reduced and they produce pistons with dimensions not in range of
tolerances. There is also possibility of other problems like human error, unprofessional worker, die
casting problem etc.
Therefore, this project is proposed to evaluate all the operations of each production line by
calculating the process capabilities and detect the problems of those machining operations whose
process capability values are not accurate.

Problem Statement
To conduct the process capability analysis of all machining operations ion Piston Production Lines,
identify improvement gaps and suggest ways to counter identified gaps.

Atlas Engineering – Piston Production Plant

Piston production plant has been manufacturing more the 150,000 pistons of two wheelers per
month. The variety of pistons that are being manufactured in Piston Production Plant are as
follows:
Piston Types
1. KYHA – CG 125
Sales Target: 46300 for May 2021
2. KTAA – CB 125
Sales Target:4900 for May 2021
3. GB5 – CD 70
Sales Target: 80484 for May 2021
4. KCC – 100 CC
Sales Target: 7200 for May 2021

4
 LITERATURE REVIEW
Process Capability:
Process capability is the repeatability and consistency of a manufacturing process relative to the
customer requirements in terms of specification limits of a product parameter. This measure is
used to objectively measure the degree to which your process is or is not meeting the
requirements.
Cp and Cpk:
Cp and Cpk, commonly referred to as process capability indices, are used to define the ability of a
process to produce a product that meets requirements. These indices, which are a fairly recent
addition to the field of statistical process management, greatly simplify the management of
statistically controlled processes.
To understand Cp and Cpk we must have an understanding of the following terms:
Specification
Specifications define product requirements. In other words, they define what is expected from an
item for it to be usable. Specifications are normally defined in terms of nominal (+/-) tolerances or
ranges (low to high. A specification for a piston ring, for example, might specify that the diameter
be 74mm +/- 0.05mm. The upper specification limit (USL) is the upper limit of the specified range.
Similarly, the lower specification limit (LSL) is the lower limit of the specified range.
Standard Deviation
The standard deviation is a measure of variability in a process. Defined as the root mean square
(RMS) deviation from average it indicates how much a process can be expected to vary from the
average. The standard deviation is normally fixed for a process that is under statistical control and
can only be affected by a process change that affects the variability in a process.
Mean
The arithmetic average of a group of values.
Cp
The Cp index is calculated using specification limits and the standard deviation only. This index
indicates, in general, whether the process is capable of producing products to specifications. No
information on the ability of the process to adhere to the target value is included in this index.
The formula for Cp is as follows:

CpK
This Cpk index is calculated using specification limits, the standard deviation, and the mean. The
index indicates whether the process is capable of producing within specification and is also an
indicator of the ability of the process to adhere to the target specification.
The formula for Cpk is as follows:

5
Cp Acceptable Range:
Following table shows the ranges of Cp values.
Sr. No. Cp Range Remarks
1. 0.0 – 0.5 Not acceptable
2. 0.5 – 1.0 Acceptable
3. 1.0 – onwards Excellent

DATA ANALYSIS AND CALCULATIONS

Data Collection
In order to determine the process capabilities of machining operations. Various dimensions of the
pistons are to be measured and recorded. In this regard various parameters are taken in to
account. Some of them are listed below:
1. Production lines
2. Operations

Production Lines:
There are 6 Production lines in Piston production department, all lines are chosen and data from
these production lines is recorded. Following pistons were being manufactured at their respective
Production Line:

Production Line Piston

1 GB-5
2 GB- 5
3 KTA
4 KYHA
5 CG- 125
6 GB-5

Operations:
The operations involved in the manufacturing of piston from the casted piston to fully manufacture
are listed below:
1. Proof Turning
Rough Machining of Outer diameter of piston

2. Seat Machining
Seat Machining involves Semi finished skirt Diameter, Inside Bore and Central drill hole.

6
 3. Grooving
Grooving involve semi-finished crown diameter, Grooving and Chamfering.

4. Taper and Straight Drill

Straight & Tapered Drilling of the piston for oil flow.

5. Rough and Fine Boring

Rough and Fine Boring for the gudgeon pin.

6. Lock Grooving and Burnishing

Lock grooving for the fitment of circlip and removal of burrs.

7. Copy Turning
Copy Turning of Outer Diameter of Piston.

8. Head Shape
Flattening of the piston head.

Dimensions (USL, LSL)

All the dimensions of the Pistons have Upper Specification limit and Lower specification limit. The
important dimensions are chosen and their USL and LSL are defined. Dimensions along with their
USL and LSL are Listed Below according to the Piston Type and Production Line.

PRODUCTION LINE 1, GB–5 Piston

Operations Dimensions USL LSL
Seat Machining Total Height 40.8 40.6
Seat Diameter 44.53 44.5
Grooving Top Ring Root Diameter 41.5 41.4
Compression Ring Root Diameter 41.7 41.6
Oil Ring Root Diameter 42.1 42
Top Groove Inclination 0.07 0
Rough and finish Bore Bore Dia 1 13.008 13.002
Bore Dia 2 13.008 13.002
Bore Inclination 0.06 0
Bore Offset 0.9 0.7
Comp Height 18.8 18.6
Lock Grooving and Burnishing Lock Dia 1 14.3 14.2
Lock Dia 2 14.3 14.2
Lock Roundness 1 0.1 0
Lock Roundness 2 0.1 0
Copy Turning OD 2mm 46.995 46.98
OD 7mm 46.995 46.98
OD 20mm 46.885 46.87
Ovality 0.27 0.25

7
PRODUCTION LINE 2, GB–5 Piston
Operations Dimensions USL LSL
Seat Machining Total Height 40.8 40.6
Seat Diameter 44.53 44.5
Grooving Top Ring Root Diameter 41.5 41.4
Compression Ring Root Diameter 41.7 41.6
Oil Ring Root Diameter 42.1 42
Top Groove Inclination 0.07 0
Rough and finish Bore Bore Dia 1 13.008 13.002
Bore Dia 2 13.008 13.002
Bore Inclination 0.06 0
Bore Offset 0.9 0.7
Comp Height 18.8 18.6
Lock Grooving and Burnishing Lock Dia 1 14.3 14.2
Lock Dia 2 14.3 14.2
Lock Roundness 1 0.1 0
Lock Roundness 2 0.1 0
Copy Turning OD 2mm 46.995 46.98
OD 7mm 46.995 46.98
OD 20mm 46.885 46.87
Ovality 0.27 0.25

PRODUCTION LINE 3, KTA Piston

Operations Dimensions USL LSL
Seat Machining Total Height 41.5 41.3
Seat Diameter 52.53 52.47
Grooving Top Ring Root Diameter 50.4 50.3
Compression Ring Root Diameter 50.65 50.55
Oil Ring Root Diameter 50.8 50.7
Top Groove Inclination 0.072 0
Rough and finish Bore Bore Dia 1 15.008 15.002
Bore Dia 2 15.008 15.002
Bore Inclination 0.06 0
Bore Offset 0.85 0.65
Comp Height 21.5 21.3
Lock Grooving and Lock Dia 1 16.5 16.4
Burnishng
Lock Dia 2 16.5 16.4
Lock Roundness 1 0.1 0
Lock Roundness 2 0.1 0
Copy Turning OD 2mm 56.49 56.47
OD 7mm 56.49 56.47
OD 20mm 56.484 56.464
Ovality 0.272 0.252

8
PRODUCTION LINE 4, KYHA Piston
Operations Dimensions USL LSL
Seat Machining Total Height 49.54 49.34
Seat Diameter 53.53 53.47
Grooving Top Ring Root Diameter 50.4 50.3
Compression Ring Root Diameter 50.6 50.45
Oil Ring Root Diameter 51 50.8
Top Groove Inclination 0.07 0
Rough and finish Bore Bore Dia 1 15.008 15.002
Bore Dia 2 15.008 15.002
Bore Inclination 0.06 0
Bore Offset 0.55 0.45
Comp Height 23.05 22.95
Lock Grooving and Lock Dia 1 16.3 16.2
Burnishng
Lock Dia 2 16.3 16.2
Lock Roundness 1 0.1 0
Lock Roundness 2 0.1 0
Copy Turning OD 2mm 56.49 56.47
OD 7mm 56.49 56.47
OD 20mm 56.472 56.452
Ovality 0.26 0.24

PRODUCTION LINE 5, CG-125 Piston

Operations Dimensions USL LSL
Seat Machining Total Height 49.6 49.4
Seat Diameter 53.53 53.5
Grooving Top Ring Root Diameter 51.1 51
Compression Ring Root Diameter 51.1 51
Oil Ring Root Diameter 51.1 51
Top Groove Inclination 0.07 0
Rough and finish Bore Bore Dia 1 15.008 15.002
Bore Dia 2 15.008 15.002
Bore Inclination 0.06 0
Bore Offset 0.55 0.45
Comp Height 23.05 22.95
Lock Grooving and Lock Dia 1 16.3 16.2
Burnishng
Lock Dia 2 16.3 16.2
Lock Roundness 1 0.1 0
Lock Roundness 2 0.1 0
Copy Turning OD 2mm 57.49 57.47
OD 7mm 57.49 57.47
OD 20mm 57.472 57.452
Ovality 0.26 0.24

9
PRODUCTION LINE 6, GB-5 Piston
Operations Dimensions USL LSL
Seat Machining Total Height 40.8 40.6
Seat Diameter 44.53 44.5
Grooving Top Ring Root Diameter 41.5 41.4
Compression Ring Root Diameter 41.7 41.6
Oil Ring Root Diameter 42.1 42
Top Groove Inclination 0.07 0
Rough and finish Bore Bore Dia 1 13.008 13.002
Bore Dia 2 13.008 13.002
Bore Inclination 0.06 0
Bore Offset 0.9 0.7
Comp Height 18.8 18.6
Lock Grooving and Lock Dia 1 14.3 14.2
Burnishing
Lock Dia 2 14.3 14.2
Lock Roundness 1 0.1 0
Lock Roundness 2 0.1 0
Copy Turning OD 2mm 46.997 46.98
OD 15mm 46.995 46.98
OD 26mm 46.885 46.87
Ovality 0.27 0.25

DIMENSIONS MEASURING GAUGES:

Pin Bore Diameter:

Figure Air Mercer Gauge

10
Copy Turning:

Figure 1 copy Turning gauge

Bore Inclination:

Figure 2 Bore Inclination Gauge

11
Total Height:

Figure 4 Total Height by dial indicator

Compression Height:

`
Figure 5 Compression Height Gauge

12
Lock Roundness:

Figure 6 Lock Roundness Gauge

Ring Root Diameter:

Figure 7 Ring root diameter Gauge

13
Seat Height:

Figure 8 Seat Diameter Gauge

PROCESS CAPABILITY CALCULATIONS:

Process capabilities for the Machining operations are calculated at each Production Line.
A total of 15 Pistons from each production line were picked up and the dimensions were measured
and recorded.
In the listed table below, Number 1-15 is showing number of pistons.
PRODUCTION LINE 1, GB-5
Top Ring Compression Oil Ring
Total Seat Top Groove
Dimensions Root Ring Root Root
Height Diameter Inclination
Diameter Diameter Diameter
USL 40.8 44.53 41.5 41.7 42.1 0.07
LSL 40.6 44.5 41.4 41.6 42 0
1 40.61 43.8 41.41 41.65 42.05 0.13
2 40.61 43.84 41.42 41.64 42.07 0.13
3 40.6 43.84 41.41 41.64 42.07 0.12
4 40.59 43.86 41.42 41.64 42.06 0.13
5 40.6 43.85 41.42 41.65 42.07 0.09
6 40.62 43.85 41.42 41.65 42.06 0.13
7 40.62 43.86 41.42 41.64 42.07 0.09
8 40.6 43.84 41.42 41.64 42.07 0.12
9 40.61 43.85 41.41 41.64 42.06 0.12
10 40.6 43.85 41.42 41.64 42.07 0.14
11 40.61 43.84 41.42 41.64 42.06 0.11
12 40.6 43.85 41.42 41.63 42.07 0.11
13 40.61 43.86 41.42 41.64 42.07 0.12
14 40.6 43.85 41.42 41.64 42.07 0.12
15 40.6 43.85 41.42 41.64 42.07 0.11
Mean 40.60533 43.846 41.418 41.64133333 42.066 0.116153846
Standard Deviation 0.008055 0.014048 0.004 0.004988877 0.0061101 0.013888823
Cp=(USL-LSL)/6σ 4.138029 0.355934 4.1666667 3.340765524 2.72772363 0.840003976

14
 Bore Bore Comp Lock Dia
Dimensions Bore Dia 1 Bore Dia 2 Lock Dia 1
Inclination Offset Height 2
USL 13.008 13.008 0.06 0.9 18.8 14.3 14.3
LSL 13.002 13.002 0 0.7 18.6 14.2 14.2
1 13.007 13.007 0.04 0.75 18.7 14.26 14.21
2 13.005 13.008 0.02 0.74 18.68 14.25 14.225
3 13.008 13.007 0.03 0.77 18.66 14.26 14.23
4 13.006 13.005 0.03 0.77 18.65 14.28 14.24
5 13.005 13.004 0.04 0.74 18.69 14.27 14.26
6 13.005 13.007 0.01 0.78 18.68 14.31 14.20
7 13.005 13.005 0.03 0.78 18.73 14.29 14.26
8 13.006 13.007 0.02 0.76 18.70 14.29 14.21
9 13.006 13.008 0.01 0.76 18.63 14.30 14.21
10 13.007 13.006 0.02 0.75 18.73 14.31 14.2
11 13.004 13.005 0.05 0.76 18.74 14.23 14.24
12 13.003 13.005 0.02 0.77 18.71 14.31 14.25
13 13.006 13.007 0.02 0.75 18.64 14.27 14.25
14 13.005 13.006 0.03 0.78 18.72 14.31 14.22
15 13.009 13.010 0.01 0.77 18.71 14.28 14.26
Mean 13.0058 13.00646667 0.0253333 0.762 18.69133 14.281333 14.231
Standard
0.001469694 0.00149963 0.0114698 0.013266 0.033039 0.0239072 0.021307
Deviation
Cp=(USL-
0.680413817 0.666831337 0.8718573 2.512595 1.008918 0.6971392 0.782205
LSL)/6σ

Lock
Lock
Dimensions Roundness OD 2mm OD 7mm OD 20mm Ovality
Roundness 1
2
USL 0.1 0.1 46.995 46.995 46.885 0.27
LSL 0 0 46.98 46.98 46.87 0.25
1 0.04 0.04 46.987 46.985 46.878 0.272
2 0.08 0.08 46.986 46.983 46.875 0.263
3 0.09 0.08 46.993 46.991 46.876 0.274
4 0.1 0.16 46.99 46.987 46.877 0.255
5 0.09 0.07 46.984 46.983 46.877 0.26
6 0.1 0.06 46.99 46.988 46.877 0.259
7 0.18 0.04 46.987 46.988 46.879 0.261
8 0.05 0.08 46.986 46.987 46.879 0.261
9 0.13 0.02 46.99 46.989 46.879 0.26
10 0.14 0.08 46.983 46.983 46.877 0.275
11 0.13 0.03 46.982 46.985 46.873 0.282
12 0.12 0.05 46.987 46.985 46.875 0.275
13 0.13 0.09 46.983 46.987 46.872 0.255
14 0.05 0.04 46.983 46.983 46.872 0.265
15 0.03 0.02 46.991 46.989 46.876 0.275
Mean 0.096666667 0.062667 46.9868 46.9862 46.8761333 0.266133
Standard Deviation 0.04093355 0.034538 0.00329 0.00248193 0.00227645 0.008253
Cp=(USL-LSL)/6σ 0.407163964 0.482557 0.759788 1.00727871 1.0982014 0.403883

15
 X Bar Graph

Production line 1
5

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Cp

PRODUCTION LINE 2, GB-5

Top Ring Compression Oil Ring
Total Seat Top Groove
Dimensions Root Ring Root Root
Height Diameter Inclination
Diameter Diameter Diameter
USL 40.8 44.53 41.5 41.7 42.1 0.07
LSL 40.6 44.5 41.4 41.6 42 0
1 40.56 43.98 41.44 41.64 42.04 0.06
2 40.56 43.99 41.45 41.64 42.04 0.12
3 40.55 44 41.45 41.65 42.06 0.05
4 40.57 43.97 41.45 41.65 42.06 0.05
5 40.56 43.98 41.44 41.65 42.06 0.08
6 40.58 43.99 41.44 41.64 42.07 0.05
7 40.57 43.99 41.44 41.64 42.07 0.06
8 40.56 43.99 41.45 41.64 42.05 0.06
9 40.56 44 41.44 41.64 42.07 0.06
10 40.57 43.98 41.44 41.64 42.06 0.05
11 40.55 43.99 41.44 41.64 42.05 0.05
12 40.56 43.98 41.45 41.64 42.07 0.04
13 40.55 43.99 41.45 41.65 42.06 0.05
14 40.57 43.98 41.44 41.64 42.06 0.07
15 40.58 43.98 41.44 41.64 42.07 0.05
Mean 40.56333 43.986 41.444 41.64266667 42.0593333 0.055384615
Standard
Deviation 0.009428 0.008 0.004898979 0.004422166 0.00997775 0.010088367
Cp=(USL-LSL)/6σ 3.535534 0.625 3.402069087 3.768891807 1.67038276 1.156447492

Bore Bore Comp Lock Dia

Dimensions Bore Dia 1 Bore Dia 2
Inclination Offset Height 1
USL 13.008 13.008 0.06 0.85 18.8 14.3
LSL 13.002 13.002 0 0.65 18.6 14.2
1 13.005 13.005 0.01 0.82 18.74 14.27
2 13.004 13.008 0.03 0.83 18.70 14.27
3 13.005 13.005 0.0 0.83 18.72 14.25
4 13.007 13.008 0.11 0.86 18.76 14.27
5 13.005 13.008 0.02 0.84 18.73 14.26
6 13.006 13.007 0.05 0.82 18.72 14.27
16
 7 13.004 13.005 0.0 0.81 18.72 14.25
8 13.005 13.005 0.01 0.80 18.68 14.27
9 13.008 13.009 0.02 0.83 18.73 14.27
10 13.007 13.007 0.02 0.85 18.72 14.28
11 13 13 0.03 0.84 18.72 14.26
12 13.005 13.004 0.06 0.81 18.74 14.26
13 13.004 13.006 0.06 0.83 18.8 14.28
14 13.004 13.004 0.02 0.84 18.72 14.26
15 13.003 13.004 0.01 0.84 18.69 14.26
Mean 13.00526667 13.0062 0.032 0.83 18.72267 14.26533
Standard Deviation 0.001388844 0.001681269 0.026633312 0.0154919 0.020483 0.008844
Cp=(USL-LSL)/6σ 0.720023041 0.594788689 0.375469631 2.1516574 1.627361 1.884446

Lock Lock
OD
Dimensions Lock Dia 2 Roundness Roundness OD 2mm OD 7mm Ovality
20mm
1 2
USL 14.3 0.1 0.1 46.995 46.995 46.963 0.27
LSL 14.2 0 0 46.98 46.98 46.948 0.25
1 14.29 0.04 0.02 46.989 46.988 46.94 0.257
2 14.28 0.05 0.06 46.985 46.984 46.948 0.258
3 14.25 0.03 0.05 46.992 46.984 46.949 0.256
4 14.28 0.03 0.02 46.993 46.983 46.947 0.259
5 14.23 0.04 0.03 46.984 46.983 46.948 0.255
6 14.28 0.04 0.04 46.991 46.984 46.948 0.253
7 14.27 0.04 0.06 46.99 46.982 46.948 0.255
8 14.25 0.03 0.04 46.995 46.984 46.949 0.26
9 14.28 0.04 0.05 46.988 46.98 46.948 0.26
10 14.26 0.03 0.02 46.98 46.98 46.947 0.264
11 14.26 0.03 0.04 46.986 46.984 46.947 0.259
12 14.24 0.03 0.04 46.99 46.98 46.946 0.252
13 14.26 0 0.05 46.987 46.984 46.948 0.255
14 14.25 0.02 0.05 46.991 46.984 46.947 0.252
15 14.25 0.01 0.03 46.988 46.985 46.948 0.26
Mean 14.262 0.0306667 0.04 46.9886 46.98327 46.9472 0.257
Standard Deviation 0.0168127 0.0123648 0.013165612 0.00370225 0.002048 0.002072 0.0033066
Cp=(USL-LSL)/6σ 0.9913145 1.3479097 1.265924209 0.67526476 1.220521 1.206543 1.0080973

X bar graph

Production line 2
5
4
3
2
1
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Cp

17
PRODUCTION LINE 3, KTA Piston
Top Ring Compression Oil Ring
Total Seat Top Groove
Dimensions Root Ring Root Root
Height Diameter Inclination
Diameter Diameter Diameter
USL 41.5 52.53 50.4 50.65 50.8 0.072
LSL 41.3 52.47 50.3 50.55 50.7 0
1 41.32 52.5 50.37 50.58 50.75 0.05
2 41.33 52.51 50.36 50.59 50.76 0.06
3 41.32 52.52 50.36 50.58 50.75 0.05
4 41.38 52.5 50.34 50.58 50.76 0.07
5 41.32 52.5 50.34 50.59 50.75 0.08
6 41.3 52.49 50.33 50.58 50.76 0.05
7 41.4 52.51 50.36 50.57 50.76 0.06
8 41.31 52.51 50.34 50.57 50.75 0.06
9 41.32 52.5 50.35 50.58 50.75 0.07
10 41.33 52.49 50.34 50.58 50.75 0.07
11 41.32 52.5 50.36 50.59 50.75 0.05
12 41.31 52.5 50.34 50.59 50.76 0.07
13 41.32 52.49 50.35 50.58 50.75 0.05
14 41.33 52.5 50.35 50.59 50.75 0.05
15 41.33 52.51 50.35 50.58 50.75 0.05
Mean 41.32933 52.502 50.349333 50.582 50.7533333 0.06
Standard Deviation 0.025421 0.008327 0.0106249 0.006531973 0.00471405 0.01037749
Cp=(USL-LSL)/6σ 1.311257 1.200961 1.5686395 2.551551815 3.53553391 1.156348934

Bore Bore Comp

Dimensions Bore Dia 1 Bore Dia 2 Lock Dia 1
Inclination Offset Height
USL 15.008 15.008 0.06 0.85 21.5 16.5
LSL 15.002 15.002 0 0.65 21.3 16.4
1 15.004 15.003 0.1 0.77 21.39 16.45
2 15.003 15.004 0.02 0.74 21.40 16.42
3 15.005 15.003 0.04 0.78 21.41 16.43
4 15.004 15.006 0.02 0.78 21.47 16.48
5 15.002 15.003 0.01 0.75 21.41 16.42
6 15.001 15.003 0.05 0.75 21.37 16.41
7 15.003 15.003 0.01 0.73 21.37 16.4
8 15.003 15.004 0.05 0.74 21.43 16.43
9 15.001 15.002 0.01 0.77 21.35 16.43
10 15.002 15.003 0.31 0.77 21.36 16.42
11 15 15 0.04 0.77 21.36 16.42
12 15.005 15.006 0.07 0.78 21.41 16.41
13 15.003 15.003 0.03 0.74 21.39 16.46
14 15.007 15.006 0.01 0.77 21.35 16.39
15 15.005 15.007 0.1 0.77 21.38 16.44
Mean 15.00346667 15.003933 0.058 0.760667 21.39 16.42733
Standard Deviation 0.00158605 0.0014817 0.073412 0.016519 0.0318329 0.022351
Cp=(USL-LSL)/6σ 0.630497028 0.6748819 0.136217 2.017836 1.0471348 0.745687

18
 Lock Lock
Lock Dia
Dimensions Roundness Roundness OD 2mm OD 7mm OD 20mm Ovality
2
1 2
USL 16.5 0.1 0.1 56.49 56.49 56.484 0.272
LSL 16.4 0 0 56.47 56.47 56.464 0.252
1 16.44 0.15 0.05 56.471 56.481 56.469 0.256
2 16.41 0.05 0.12 56.471 56.48 56.468 0.254
3 16.49 0.03 0.05 56.481 56.481 56.474 0.262
4 16.46 0.05 0.05 56.48 56.473 56.472 0.259
5 16.47 0.03 0.05 56.474 56.484 56.67 0.268
6 16.46 0.03 0.11 56.478 56.486 56.469 0.262
7 16.41 0.04 0.12 56.485 56.481 56.467 0.265
8 16.48 0.05 0.03 56.483 56.487 56.473 0.26
9 16.44 0.04 0.02 56.478 56.48 56.472 0.255
10 16.46 0.04 0.02 56.475 56.481 56.468 0.265
11 16.48 0.03 0.02 56.482 56.483 56.469 0.257
12 16.49 0.04 0.05 56.481 56.484 56.473 0.26
13 16.4 0.04 0.02 56.485 56.484 56.47 0.256
14 16.46 0.06 0.02 56.487 56.488 56.473 0.263
15 16.51 0.05 0.03 56.484 56.483 56.472 0.264
Mean 16.45733 0.048667 0.050666667 56.47966667 56.4824 56.469 0.2604
Standard
Deviation 0.031084 0.035302 0.035301873 0.004894441 0.00347946 0.0497748 0.0040628
Cp=(USL-
LSL)/6σ 0.53618 0.472118 0.472118484 0.681044707 0.95800208 0.0669683 0.8204442

X Bar Graph

Production line 3
5

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Cp

19
PRODUCTION LINE 4, KYHA Piston
Top Ring Compression
Total Seat Oil Ring Root
Dimensions Root Ring Root
Height Diameter Diameter
Diameter Diameter
USL 49.54 53.53 50.4 50.6 51
LSL 49.34 53.47 50.3 50.45 50.8
1 49.37 53.4 50.31 50.5 50.93
2 49.35 53.4 50.31 50.54 50.98
3 49.39 53.42 50.32 50.52 50.99
4 49.37 53.41 50.33 50.49 50.96
5 49.35 53.4 50.32 50.53 50.91
6 49.37 53.41 50.31 50.48 50.94
7 49.34 53.41 50.34 50.49 50.93
8 49.34 53.41 50.33 50.51 50.92
9 49.36 53.4 50.33 50.49 50.94
10 49.31 53.41 50.33 50.51 50.93
11 49.31 53.41 50.31 50.5 50.95
12 49.37 53.4 50.33 50.45 50.95
13 49.36 53.41 50.32 50.49 50.96
14 49.31 53.4 50.34 50.48 50.96
15 49.38 53.41 50.33 50.54 50.94
Mean 49.352 53.40667 50.324 50.50133333 50.946
Standard Deviation 0.024819 0.005963 0.010198 0.023626727 0.02091252
Cp=(USL-LSL)/6σ 1.343038 1.677051 1.6343011 1.058123715 1.59394178

Bore
Top Groove Bore Dia Bore Bore Comp Lock Lock
Dimension Inclinatio
Inclination 1 Dia 2 Offset Height Dia 1 Dia 2
s n
USL 0.07 15.008 15.008 0.06 0.55 23.05 16.3 16.3
LSL 0 15.002 15.002 0 0.45 22.95 16.2 16.2
1 0.09 15.005 15.005 0.05 0.52 23.03 16.26 16.27
2 0.09 15.006 15.003 0.01 0.49 23.01 16.21 16.26
3 0.08 15.004 15.005 0.04 0.50 22.99 16.24 16.26
4 0.06 15.005 15.006 0.02 0.49 23.05 16.24 16.28
5 0.09 15.005 15.005 0.02 0.49 23.03 16.22 16.19
6 0.07 15.004 15.004 0.02 0.49 22.07 16.22 16.21
7 0.07 15.005 15.006 0.06 0.49 23.04 16.19 16.18
8 0.08 15.004 15.005 0.02 0.50 23.04 16.21 16.23
9 0.09 15.005 15.006 0.03 0.49 22.97 16.23 16.26
10 0.08 15.005 15.007 0.01 0.51 23.01 16.22 16.26
11 0.09 15 15 0.08 0.50 22.99 16.25 16.22
12 0.1 15.005 15.005 0.03 0.51 22.98 16.22 16.28
13 0.07 15.003 15.005 0.02 0.50 23.01 16.22 16.25
14 0.09 15.008 15.007 0.04 0.48 22.94 16.26 16.27
15 0.06 15.004 15.006 0.03 0.51 23.01 16.20 16.21
0.07923076 15.00493 15.0054 22.9446
Mean 9 3 7 0.032 0.498 7 16.226 16.242
Standard 0.01206491 0.001123 0.00108 0.010456 0.01993 0.03166
Deviation 3 5 7 0.01869 3 0.23551 3 5
Cp=(USL- 0.96699134 0.890086 0.91970 0.53503 1.593941 0.07076 0.83612 0.52634
LSL)/6σ 8 2 9 2 8 8 5 5

20
 Lock
Lock Roundness OD
Roundness OD 2mm OD 7mm Ovality
1 20mm
Dimensions 2
USL 0.1 0.1 56.49 56.49 56.472 0.26
LSL 0 0 56.47 56.47 56.452 0.24
1 0.1 0.15 56.484 56.475 56.46 0.246
2 0.12 0.11 56.473 56.47 56.461 0.256
3 0.05 0.08 56.478 56.481 56.458 0.246
4 0.12 0.1 56.476 56.477 56.452 0.245
5 0.07 0.03 56.48 56.474 56.459 0.247
6 0.05 0.03 56.478 56.471 56.459 0.248
7 0.05 0.05 56.476 56.476 56.459 0.246
8 0.02 0.09 56.489 56.481 56.454 0.25
9 0.08 0.08 56.478 56.476 56.452 0.249
10 0.05 0.04 56.476 56.478 56.453 0.249
11 0.08 0.08 56.475 56.476 56.458 0.245
12 0.09 0.03 56.481 56.48 56.458 0.25
13 0.02 0.05 56.476 56.477 56.457 0.246
14 0.03 0.04 56.478 56.474 56.458 0.248
15 0.05 0.04 56.478 56.475 56.456 0.248
Mean 0.065333333 0.06666667 56.4784 56.476067 56.45693 0.247933

Standard Deviation 0.031382939 0.03438346 0.0038088 0.0030869 0.002792 0.002695

Cp=(USL-LSL)/6σ 0.531074111 0.48472921 0.8751751 1.0798355 1.193865 1.236927

X Bar Graph

Production line 4
5

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Cp

21
 PRODUCTION LINE 5, CG-125
Top Ring Compression Oil Ring
Total Seat Top Groove
Dimensions Root Ring Root Root
Height Diameter Inclination
Diameter Diameter Diameter
USL 49.6 53.53 51.1 51.1 51.1 0.07
LSL 49.4 53.5 51 51 51 0
1 49.45 53.52 51.04 51.03 51.05 0.09
2 49.44 53.55 51.03 51.03 51.06 0.09
3 49.46 53.52 51.05 51.04 51.03 0.08
4 49.44 53.53 51.06 51.04 51.07 0.1
5 49.44 53.54 51.04 51.03 51.05 0.9
6 49.43 53.51 51.02 51.03 51.05 0.9
7 49.42 53.5 51.05 51.08 51.06 0.11
8 49.45 53.58 51.04 51.03 51.05 0.08
9 49.41 53.55 51.05 51.04 51.06 0.09
10 49.43 53.57 51.04 51.03 51.06 0.11
11 49.42 53.58 51.05 51.02 51.05 0.09
12 49.4 53.57 51.04 51.04 51.03 0.11
13 49.41 53.54 51.04 51.04 51.08 0.11
14 49.44 53.57 51.04 51.03 51.05 0.09
15 49.4 53.57 51.04 51.04 51.05 0.09
Mean 49.42933 53.54667 51.042 51.03666667 51.0533333 0.22
Standard Deviation 0.018062 0.025473 0.009092121 0.012995726 0.01247219 0.290145852
Cp=(USL-LSL)/6σ 1.845534 0.196284 1.833088938 1.28247294 1.33630621 0.040209662

Bore Bore Comp Lock Dia

Dimensions Bore Dia 1 Bore Dia 2
Inclination Offset Height 1
USL 15.008 15.008 0.06 0.55 23.05 16.3
LSL 15.002 15.002 0 0.45 22.95 16.2
1 15.005 15.007 0.06 0.46 23.02 16.21
2 15.007 15.005 0.02 0.45 22.99 16.24
3 15.004 15.005 0.04 0.45 23.04 16.21
4 15.007 15.004 0.02 0.46 23.01 16.26
5 15.005 15.003 0.02 0.48 22.98 16.2
6 15.005 15.006 0.05 0.47 23.04 16.21
7 15.004 15.006 0.0 0.44 23.05 16.23
8 15.006 15.005 0.06 0.44 23.03 16.25
9 15.006 15.006 0.06 0.47 23.05 16.22
10 15.006 15.004 0.02 0.46 23.00 16.21
11 15 15 0.03 0.45 23.06 16.25
12 15.005 15.006 0 0.48 23.04 16.21
13 15.003 15.006 0.01 0.44 23.0 16.24
14 15.008 15.006 0.02 0.46 22.99 16.22
15 15.006 15.006 0.03 0.45 22.98 16.24
Mean 15.00546667 15.00533333 0.032 0.4573333 23.01867 16.22667
Standard Deviation 0.001257864 0.00101105 0.018330303 0.0128927 0.02655 0.018135
Cp=(USL-LSL)/6σ 0.79499841 0.98907071 0.545544726 1.2927192 0.627752 0.919018

22
 Bore Bore Comp Lock Dia
Dimensions Bore Dia 1 Bore Dia 2
Inclination Offset Height 1
USL 15.008 15.008 0.06 0.55 23.05 16.3
LSL 15.002 15.002 0 0.45 22.95 16.2
1 15.005 15.007 0.06 0.46 23.02 16.21
2 15.007 15.005 0.02 0.45 22.99 16.24
3 15.004 15.005 0.04 0.45 23.04 16.21
4 15.007 15.004 0.02 0.46 23.01 16.26
5 15.005 15.003 0.02 0.48 22.98 16.2
6 15.005 15.006 0.05 0.47 23.04 16.21
7 15.004 15.006 0.0 0.44 23.05 16.23
8 15.006 15.005 0.06 0.44 23.03 16.25
9 15.006 15.006 0.06 0.47 23.05 16.22
10 15.006 15.004 0.02 0.46 23.00 16.21
11 15 15 0.03 0.45 23.06 16.25
12 15.005 15.006 0 0.48 23.04 16.21
13 15.003 15.006 0.01 0.44 23.0 16.24
14 15.008 15.006 0.02 0.46 22.99 16.22
15 15.006 15.006 0.03 0.45 22.98 16.24
Mean 15.00546667 15.00533333 0.032 0.4573333 23.01867 16.22667
Standard Deviation 0.001257864 0.00101105 0.018330303 0.0128927 0.02655 0.018135
Cp=(USL-LSL)/6σ 0.79499841 0.98907071 0.545544726 1.2927192 0.627752 0.919018

X Bar Graph

Production line 5
5

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Cp

23
 PRODUCTION LINE 6, GB-5 Piston
Total Seat Top Ring Compression Oil Ring Root
Dimensions Height Diameter Root Dia Ring Root Dia Dia
USL 40.8 44.53 41.5 41.7 42.1
LSL 40.6 44.5 41.4 41.6 42
1 40.63 43.94 41.47 41.67 42.09
2 40.68 43.93 41.47 41.68 42.08
3 40.67 43.94 41.47 41.66 42.08
4 40.67 43.93 41.47 41.66 42.08
5 40.66 43.94 41.47 41.66 42.08
6 40.65 43.94 41.47 41.66 42.07
7 40.62 43.93 41.47 41.66 42.08
8 40.66 43.94 41.46 41.66 42.07
9 40.63 43.94 41.47 41.66 42.08
10 40.63 43.94 41.47 41.66 42.09
11 40.66 43.94 41.47 41.66 42.08
12 40.64 43.93 41.47 41.67 42.08
13 40.63 43.94 41.47 41.66 42.08
14 40.65 43.94 41.47 41.66 42.09
15 40.66 43.94 41.47 41.66 42.09
Mean 40.64933 43.93733 41.469333 41.66266667 42.0813333
Standard Deviation 0.017689 0.004422 0.0024944 0.005734884 0.00618241
Cp=(USL-LSL)/6σ 1.884446 1.130668 6.681531 2.906190969 2.69581933

Top
Bore Dia Bore Dia Bore Bore Comp Lock Dia
Groove
1 2 Inclination Offset Height 1
Dimensions Inclination
USL 0.07 13.008 13.008 0.06 0.9 18.8 14.3
LSL 0 13.002 13.002 0 0.7 18.6 14.2
1 0.06 13.007 13.008 0.05 0.77 18.68 14.24
2 0.04 13.006 13.008 0.05 0.77 18.7 14.25
3 0.07 13.007 13.008 0.04 0.78 18.67 14.26
4 0.1 13.007 13.007 0.06 0.77 18.68 14.26
5 0.06 13.006 13.007 0.04 0.775 18.68 14.24
6 0.08 13.005 13.007 0.06 0.76 18.72 14.26
7 0.06 13.007 13.008 0.03 0.78 18.63 14.3
8 0.09 13.007 13.007 0.04 0.77 18.67 14.26
9 0.06 13.007 13.006 0.05 0.77 18.70 14.26
10 0.05 13.006 13.007 0.01 0.78 18.67 14.23
11 0.04 13.006 13.007 0.19 0.74 18.72 14.25
12 0.03 13.007 13.006 0.05 0.79 18.71 14.23
13 0.04 13.007 13.007 0.06 0.79 18.67 14.24
14 0.02 13.007 13.007 0.06 0.79 18.70 14.26
15 0.1 13.007 13.007 0.01 0.78 18.68 14.26
Mean 0.06 13.0066 13.00713 0.0533333 0.774333 18.68533 14.25333
Standard Deviation 0.0236643 0.000611 0.000618 0.0397772 0.012499 0.022764 0.0166
Cp=(USL-LSL)/6σ 0.4930066 1.636634 1.617492 0.2514006 2.666904 1.464269 1.004024

24
 Lock Lock
Lock Dia
Roundness Roundness OD OD
2
Dimensions 1 2 OD 2mm 15mm 26mm Ovality
USL 14.3 0.1 0.1 46.997 46.995 46.885 0.27
LSL 14.2 0 0 46.98 46.98 46.87 0.25
1 14.26 0.05 0.06 46.987 46.986 46.874 0.258
2 14.24 0.09 0.08 46.98 46.979 46.865 0.252
3 14.27 0.09 0.08 46.983 46.987 46.87 0.26
4 14.23 0.04 0.09 46.982 46.987 46.869 0.26
5 14.22 0.08 0.07 46.98 46.987 46.869 0.255
6 14.24 0.08 0.03 46.988 46.985 46.867 0.255
7 14.29 0.08 0.05 46.985 46.987 46.867 0.26
8 14.25 0.07 0.06 46.979 46.985 46.869 0.252
9 14.27 0.06 0.07 46.98 46.983 46.87 0.258
10 14.22 0.07 0.07 46.982 46.984 46.875 0.258
11 14.24 0.09 0.05 46.983 46.986 46.876 0.26
12 14.26 0.06 0.06 46.98 46.46.982 46.875 0.256
13 14.22 0.08 0.06 46.979 46.983 46.983 0.255
14 14.25 0.07 0.05 46.982 46.98 46.875 0.26
15 14.24 0.07 0.05 46.985 46.983 46.876 0.26
Mean 14.24667 0.072 0.062 46.98233 46.98443 46.87867 0.257267
Standard
Deviation 0.019889 0.0142361 0.0146969 0.002749 0.002499 0.028109 0.002816
Cp=(USL-
LSL)/6σ 0.838002 1.1707323 1.134023 1.030776 1.000408 0.088941 1.183784

X Bar Graph

Production line 6
10

0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Cp

25
 EVALUATION

EVALUATION ON CP RANGE BASIS:

The production lines are evaluated on the basis of process capabilities (Cp). On the very first, data
from 15 consecutive and random productions is collected from each operation of production lines
and the process capability of each dimension is calculated by using the formula given below.
(𝐔𝐒𝐋 − 𝐋𝐒𝐋)
𝐂𝐩 =
𝟔𝛔

PROBLEMS AND CAUSES CHART:

OPERATION PROBLEM POSSIBLE CAUSES Solution

,DIMENSION
.INSPECTION

BORE DIAMETER ROUGHNESS Casting – Varying Hardness of Inspect the casting Hardness
the casting Frequently.
Cutting Oil – Inefficient Provide adequate cutting oil
Cutting oil for machining operation

UNDERSIZING BORE Tool Wear and Tear Set the Standard for tool re-
sharpness

TOOL PATH LINES Tool Sharpness Inspect the tool tips

frequently

BORE CROSS/ BORE Die Change – Every die has Adjust and verify the bore
MISALIGNMENT different setting for special alignment at the time of die
purpose machines to machine change.
the part that has been
manufactured from the
specific die (at most 2 pistons
are used for the setting of
SPM)

BORE INCLINATION Dimension variation Seat Diameter area uncleaned
Piston Seat Pad uncleaned
Clamp Pressure
Worker ensure to clean the
jigs and fixtures.
Worker ensure to clean the
jigs and fixtures.
Inspect the pneumatic
cylinder and ensure
hydraulic pressure as per
standard.

COMPRESSION COMPRESSION Height variation from dies

HEIGHT HEIGHT VARIATION
Operator – Undersize and
oversized pistons if not
inspected and are machined in
Carefully measure the piston
height at initial phases of
production
26
 Boring operation will cause
slip tight, bore misalignment,
grooving misalignment.

LOCK DIAMETER DIMENSION Hardness of Material, Dies Inspect the casting Hardness
VARIATION Fault, worn out tool. Frequently and change tool
according to standard
frequency

Seat Diameter Diameter Size Casting- Hardness of material Inspect the casting Hardness
variation and Tool Frequently
Wear Inspect the tool tips
frequently

Top groove Tool misalignment Misalignment of Fixtures Check the groove fixtures
inclination after every 25 pistons
machining.

Compression and Exceeding the Shrinkage porosity, Supervisor must ensure that
Ring root diameter Standard drawing Slag. the respective dimensions
dimension must be checked after 10
pistons

27
CAUSES AND EFFECT DIAGRAM (FISH BONE DIAGRAM):

MACHINE METHOD
(Bore (Cutting Oil)
Misalignment)

ROUGHNESS

SLIP TIGHT

UNDER SIZE BORE

MATERIAL
MAN
(Casting, Piston
(Seat Diameter area
Height Variation, Tool
uncleaned)
Wear and tear)

MACHINE METHOD
(Clamp Pressure, --
Dies Fault)

Bore Inclination

Compression
Height

Lock Diameter

MAN MATERIAL

(Human Error, Piston (Height variation

Seat Pad uncleaned, from dies, Hardness
worn out tool. ) of Material)

28
 MACHINE METHOD

(Shrinkage --
porosity, Slag)

Seat Diameter

Top groove inclination

Compression and ring

root diameter

MAN MATERIAL

(Misalignment of (Casting- Hardness

Fixtures) of material)

CONCLUSION:

By evaluating all the machining operations in piston machining department, the conclusion obtained is that each
machining operation has some ambiguities which require a bit attention towards their specific processes, e.g.,
roughness of bore diameter of gudgeon pin due to varying hardness of die casting due to material melting issues, there
is another reason which is insufficient supply of cutting oil.

There are also some common issues occurring in each machining line like under sizing of bore due to tool wear and
tear. It also causes tool path lines on the process like proof turning, copy turning, groove inclination. All this can be
resolved if the frequency of inspection by supervisor is increased. The machining processes will also be reduced if the
quality of casting is inspected in initial phases of production.

29