Introduction

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 1
Introduction

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 2
Introduction Welcome

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 3
Introduction The TECHIZ Family

FORMATION DATE 11-06-2020

WORKING AREA ENGINE ASSEMBLY

MEETING DAY EVERY FRIDAY

PARVINDER SINGH
SURENDER KUMAR LEADER
FACILITATOR MEETING TIME 3.00 - 4.00 PM

VENUE ENGINE PLANT MEETING ROOM

PROBLEM SOLVED 02

IN PROCESS 01
AMIT SAINI
SAHAB SINGH DY. LEADER
MEMBER
PRESENTED 02

THIS PROJECT

NO. OF MEETINGS 12
ANAND MOHAN
MEMBER RAJINDER SINGH
DAVINDER SINGH MEMBER ATTENDANCE 98.5 %
MEMBER

THE MEANING OF NAME “TECHIZ” REPRESENTS AMBITION , STRENGTH,RELABILITY , DETERMINATION

AND PROFESSIONALISM.
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 4
Introduction Process flow of our working area

Title: Elimination Of Right Crankcase rejection of 125 cc model at

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Introduction Group Proceedings

TECHIZ : GROUP NAME

GREEN : SYSTEMATIC AND HONESTY
BLUE : INTEGRITY
RED : EFFICIENCY/COMPETENCY
ARROW : CONTINUOUS SUCCESS

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 6
Introduction Mission

Title: Elimination Of Right Crankcase rejection of 125 cc model at

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 Introduction Current status of previous solved problems
CURRENT STATUS OF PREVIOUS SOLVED PROBLEMS
Status before
Sl Date of Completion Implementation Current
Name of project Cause average Action taken Achievement
no. start date date status
/month

Bearing locator
Right crankcase Bearing press
18 Crankcase design change, 0 Crankcase
1 rejection BS- 6 fixture , crankcase 11.06.20 29.08.20 29.08.2020 4 TH POSITION
/month supply system till now
125cc supply
change
POKA YOKE at
Assembly at main
main conveyor
Right crankcase conveyor , 23 crankcase 0 Crankcase
2. 07.09.20 24.11.20 ,identification 24.11.2020 1 ST POSITION
model mix 100cc handling at sub /month till now
mark on BS-4
assembly
right crankcase

Plan Schedule Till Define The Problem

QC NAME :- TECHIZ DEPARTMENT :- ENGINE ASSEMBLY H.O.D : RAKESH SHARMA COORDINATOR :- D.L SIDHWANI
PROJECT :- ELIMINATION OF RIGHT CRANKCASE REJECTION 125 CC (BSVI)
REASON FOR SELECTION :- DEFECT % INCREASING,TO DECREASE REJECTION COST, TO INCREASE STRAIGHT PASS, TO INCREASE PRODUCTIVITY
TARGET PERIOD TEAM
MEASUREMENT ITEM U.O.M FROM TO FROM TO LEADER DY. LEADER MEMBER FACILITATOR
REJECTION NOS. 23 0 11-12-2020 11.03.2021 PARVINDER SINGH AMIT SAINI DAVINDER ANAND MOHAN SAHAB SINGH RAJINDER SINGH SURENDER KUMAR

MONTH Dec-20 Jan-21 Feb-21 Mar-21

STEP NO. STEP DESCRIPTION
DATE 11 18 25 8 15 22 29 5 12 19 26 4 11

1 IDENTIFICATION OF THE PROBLEM PLAN

ACTUAL

2 SELECTION OF THE PROBLEM PLAN

ACTUAL
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 8
PLANT SHUTDOWN FROM 27 DEC 20 TO 04 JAN 21
Step -1 Identification of problem 1.2:-List of problems (Engine assembly)
SL NO. AREA PROBLEM SL NO. AREA PROBLEM

1 RIGHT CRANKCASE MODEL MIX (i3S) 27 CRANKCASE AND CYLINDER HEAD PUNCTURE

2 ALTERNATE CURRENT GENERATOR MODEL MIX 28 LEFT AND RIGHT CRANKCASE SURFACE UNCLEAN

3 COUNTER SHAFT SPROCKET BOLT LOOSE 29 CRANKCASE SURFACE UP/DOWN

4 LOCK NUT B FITMENT TIGHT IN MAIN SHAFT 30 CRANKCASE WITHOUT OPERATION

5 CYLINDER HEAD SHAFT ROCKER ARM FITMENT TIGHT 31 PUSH ROD THREAD AREA /SURFACE DAMAGE
Sub Assembly

Leakage stage
6 CYLINDER HEAD FINS BROKEN 32 CRANKCASE PUNCTURE /BLOW HOLE
7 CAM SHAFT DOWEL FITMENT TIGHT 33 COUNTER SHAFT OIL SEAL LEAKAGE
8 TAPPET ADJUSTING NUT/SCREW TIGHT 34 SELF MOTOR O RING LEAKAGE
9 COUNTERSHAFT FITMENT TIGHT IN CRANKCASE 35 CRACK AT CRANKCASE AND CRANKCASE COVER RIGHT
10 BOLT TENSIONER ARM FITMENT TIGHT 36 OIL PUMP GEAR MISSING
11 RIGHT CRANKCASE REJECTION 125CC MODEL 37 ALTERNATE CURRENT GENERATOR OIL SEAL LEAKAGE
12 CRANKCASE BOLT STUD REJECTION 38 LEFT AND RIGHT CRANKCASE SURFACE UP/DOWN

13 OIL PUMP MOVEMENT TIGHT 39 KICK NOISE

14 DRIVE SPROCKET MODEL MIXING 40 TAPPET NUT OPEN /LOOSE
15 CRANKSHAFT THREAD DAMAGE/WITHOUT THREAD 41 CRANKSHAFT RUBBING NOISE

Vehicle Rectification
16 HS BOLT HOLE OUT IN LEFT CRANKCASE 42 LEFT CRANKCASE DIA 115 OVERSIZE/UNDER SIZE
Conveyor Line

17 RIGHT CRANKCASE COVER BOLT LOOSE/FREE 43 ENGINE JERKING

18 MAIN SHAFT TIGHT IN CRANKCASE 44 RIGHT CRANKCASE COVER SCRATCH
19 DENT IN MAIN SHAFT COTTER GROOVE 45 ENGINE NEUTRAL DRIVE
20 STEP IN CYLINDER HEAD STUD HOLE 46 SELF GEAR NOISE DURING STARTING OF VEHICLE
21 CYLINDER HEAD ROCKER ARM FITMENT TIGHT 47 KICK MOVEMENT FREE
22 RIGHT CRANKCASE COVER OIL HOLE BLOCK 48 KICK RETURN RUBBING NOISE
23 LEFT AND RIGHT CRANKCASE WITHOUT THREAD 49 ENGINE DUPLICATE/ NUMBER PUNCHING MISMATCH
24 RIGHT CRANKCASE OIL HOLE GALLERY BLOCK 50 ENGINE NUMBER DIGITS VARIATION
25 CYLINDER HEAD BOLT STUD THREAD FREE /DAMAGE 51 NO START OF VEHICLE
26 PUSH ROD ASSEMBLY FITMENT TIGHT IN CRANKCASE 52 ENGINE OIL LESS /NIL IN VEHICLE

Title: Elimination Of Right Crankcase rejection of 125 cc model at

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Step -2 Selection of problem 2.1:-Categorization of problems
SL SL
PROBLEM CATEGORY PROBLEM CATEGORY
NO. NO.
1 RIGHT CRANKCASE MODEL MIX (i3S) A 14 DRIVE SPROCKET MODEL MIXING A/K

A CRANKSHAFT THREAD DAMAGE/WITHOUT B

2 ALTERNATE CURRENT GENERATOR MODEL MIX 15
THREAD

3 COUNTER SHAFT SPROCKET BOLT LOOSE A 16 HS BOLT HOLE OUT IN LEFT CRANKCASE B

4 LOCK NUT B FITMENT TIGHT IN MAIN SHAFT B 17 RIGHT CRANKCASE COVER BOLT LOOSE/FREE A/K

CYLINDER HEAD SHAFT ROCKER ARM FITMENT B

5 18 MAIN SHAFT TIGHT IN CRANKCASE B
TIGHT

6 CYLINDER HEAD FINS BROKEN A 19 DENT IN MAIN SHAFT COTTER GROOVE A

7 CAM SHAFT DOWEL FITMENT TIGHT B 20 STEP IN CYLINDER HEAD STUD HOLE B

8 TAPPET ADJUSTING NUT/SCREW TIGHT A/K 21 CYLINDER HEAD ROCKER ARM FITMENT TIGHT B

9 COUNTERSHAFT FITMENT TIGHT IN CRANKCASE B 22 RIGHT CRANKCASE COVER OIL HOLE BLOCK A/K

10 BOLT TENSIONER ARM FITMENT TIGHT A LEFT AND RIGHT CRANKCASE WITHOUT B
23
THREAD

11 RIGHT CRANKCASE REJECTION 125CC MODEL A 24 RIGHT CRANKCASE OIL HOLE GALLERY BLOCK A

12 CRANKCASE BOLT STUD REJECTION A CYLINDER HEAD BOLT STUD THREAD FREE A/K
25
/DAMAGE

OIL PUMP MOVEMENT TIGHT A/K PUSH ROD ASSEMBLY FITMENT TIGHT IN B
13 26
CRANKCASE
*A/K ( CAN BE SOLVE WITH SMALL KAIZEN)
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 10
Step -2 Selection of problem 2.1:-Categorization of problems
SL SL
PROBLEM CATEGORY PROBLEM CATEGORY
NO. NO.
27 CRANKCASE AND CYLINDER HEAD PUNCTURE B 40 TAPPET NUT OPEN /LOOSE A

LEFT AND RIGHT CRANKCASE SURFACE

28 B 41 CRANKSHAFT RUBBING NOISE B
UNCLEAN

29 CRANKCASE SURFACE UP/DOWN B LEFT CRANKCASE DIA 115 OVERSIZE/UNDER B

42
SIZE

30 CRANKCASE WITHOUT OPERATION B 43 ENGINE JERKING A

31 PUSH ROD THREAD AREA /SURFACE DAMAGE B 44 RIGHT CRANKCASE COVER SCRATCH A

32 BLOW HOLE IN CYLINDER HEAD /CRANKCASE B 45 ENGINE NEUTRAL DRIVE A

33 COUNTER SHAFT OIL SEAL LEAKAGE A/K SELF GEAR NOISE DURING STARTING OF A
46
VEHICLE

34 SELF MOTOR O RING LEAKAGE A/K 47 KICK MOVEMENT FREE A

CRACK AT CRANKCASE AND CRANKCASE COVER

35 B 48 KICK RETURN RUBBING NOISE B
RIGHT

36 OIL PUMP GEAR MISSING A ENGINE DUPLICATE/ NUMBER PUNCHING A/K

49
MISMATCH
ALTERNATE CURRENT GENERATOR OIL SEAL
37 A/K 50 ENGINE NUMBER DIGITS VARIATION A/K
LEAKAGE
LEFT AND RIGHT CRANKCASE SURFACE
38 A 51 NO START OF VEHICLE A
UP/DOWN

39 KICK NOISE A 52 ENGINE OIL LESS / NIL IN VEHICLE A/K

*A/K ( CAN BE SOLVE WITH SMALL KAIZEN)
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 11
Step -2 Selection of problem 2.1:-Categorization of problems
ABC Classification
Minimum use of other department and use of simple tools / techniques
A Category Problem
in solving them. A/K Type problems can be solved through simple Kaizen

Involvement of other department as well as more use of simple tools /

B Category Problem
techniques in solving them

Management sanction and support may be needed in implementation

C Category Problem
of solution

Problems Identified Resolved Unsolved 25

21
20 19
A type 19 0 19
15 12
A /K type 12 12 0
10
B type 21 0 21
5
0
C type 0 0 0 0
A A/K B C
Total 52 12 40
A A/K B C

Conclusion :-Hence we found 31 Problems in A category out of A category 31 problems, 12 problems solved
with small kaizen,08 problems taken by other QC,SIT and CFT rest of 11 problems carry forwarded
Title: Elimination Of Right Crankcase rejection of 125 cc model at
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Step -2 Selection of problem 2.1:-Categorization of problems
List Of 08 Problems Taken By Other QCC & SIT

SL
PROBLEM QCC SIT
NO.

1 COUNTERSHAFT SPROCKET BOLTLOOSE IN 100CC SUPER

2 SELF GEAR NOISE DURING STARTING OF VEHICLE EXTREME

3 DENT IN MAIN SHAFT COTTER GROOVE LAKSHYA

4 RIGHT CRANKCASE MODEL MIX (i3S) GENIUS

5 RIGHT CRANKCASE COVER SCRATCH KIRAN

6 OIL PUMP GEAR MISSING TRIUMPH

7 RIGHT CRANKACSE OIL HOLE GALLERY BLOCK ATMOS

8 CRANKCASE BOLT STUD REJECTION AMAGE AND CREATE

Title: Elimination Of Right Crankcase rejection of 125 cc model at

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Step -2 Selection of problem 2.2:-Problem Matrix
11 PROBLEMS IDENTIFIED IN “A” CATEGORY
Sl Cause Solution
Problem
no. Known Unknown Known Unknown
1 ALTERNATE CURRENT GENERATOR MODEL MIX

2 CYLINDER HEAD FINS BROKEN

3 BOLT TENSIONER ARM FITMENT TIGHT

4 RIGHT CRANKCASE REJECTION 125CC MODEL

5 LEFT AND RIGHT CRANKCASE SURFACE UP/DOWN

6 KICK NOISE

7 TAPPET NUT OPEN /LOOSE

8 ENGINE JERKING

9 ENGINE NEUTRAL DRIVE

10 KICK MOVEMENT FREE

11 NO START OF VEHICLE

Conclusion :- Shortlisted Problems on the basis of cause & solution known & unknown
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 15
Step -2 Selection of problem 2.3:- Prioritization of Problems
Prioritization of “A” category problems
MONTH Defects at engine assembly 100.00
SL 105 96.19
PROBLEM Average 100
NO Sept-20 Oct-20 Nov-20 100 89.52

Right crankcase 90 80.95

1 rejection in 125cc 33 32 28 31 80
model 80
67.62
70
2 Kick noise 18 24 24 22
VITAL FEW USEFUL MANY 60
60
50.48

No. of defects

Comm. %age
Left and right 50
3 crankcase surface 22 19 13 18
up/down 40
40
29.52
4 Engine jerking 7 14 11 14 30

20 20
Engine neutral 31
5 8 6 13 9 22
drive 10 18
14
9 7 4
0 0
6 Kick movement free 5 4 12 7 Right Kick noise Left and right Engine jerking Engine neutral Kick No start of
crankcase crankcase drive movement vehicle
rejection in surface free
7 No start of vehicle 3 2 7 4 125cc model up/down

TOTAL 96 101 108 105 Problems

(Average Data of September 20 to November 20)
Conclusion :- Right crankcase rejection 125cc is highest thus we selected as our theme
Title: Elimination Of Right Crankcase rejection of 125 cc model at
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Step -3 Define the problem 3.1:- Problem statement

Title: Elimination Of Right Crankcase rejection of 125 cc model at

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Step -3 Define the problem 3.1:- Department`s Objective

Achieve Operation Excellence

• Deliver to customer’s requirements
- Focus, Prioritize, Plan
- Robust and accurate forecasting
- Accurate with whatever we do and be predictable
- Be flexible in dealing with ever changing environment
- Strategy to work on capacity constraint
• Be incident and injury free
• Flawlessly execute key programs
- Time to market
Drive Cost & Productivity Improvement

Maximize internal assembly straight pass

Manning ratio improvement
Flawless assembly/test cost/productivity improvement Program
implementation
Instill cost awareness in all levels of department
Direct Material/Indirect Material wastage reduction
Capitalize on existing equipment for reuse
.....PROJECT SELECTED LINK TO DEPARTMENT FOCUS
Title: Elimination Of Right Crankcase rejection of 125 cc model at
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Step -3 Define the problem 3.2:- Plan of Action
QC NAME :- TECHIZ DEPARTMENT :- ENGINE ASSEMBLY H.O.D : RAKESH SHARMA COORDINATOR :- D.L SIDHWANI
PROJECT :- ELIMINATION OF RIGHT CRANKCASE REJECTION OF 125 CC AT CRANKSHAFT PRESS MACHINE
REASON FOR SELECTION :- DEFECT % INCREASING,TO DECREASE REJECTION COST, TO INCREASE STRAIGHT PASS, TO INCREASE PRODUCTIVITY
TARGET PERIOD TEAM
MEASUREMENT ITEM U.O.M FROM TO FROM TO LEADER DY. LEADER MEMBER FACILITATOR
REJECTION NOS. 31 0 11.12.2020 11.03.2021 PARVINDER SINGH AMIT SAINI DAVINDER ANAND MOHAN SAHAB SINGH RAJINDER SINGHSURENDER KUMAR

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine LEGEND :- Plan Actual
19
PLANT SHUTDOWN FROM 27 DEC 20 TO 04 JAN 21
Step -3 Define the problem 3.2:- Plan of Action

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine LEGEND :- Plan Actual
20
Step -3 Define the problem 3.3:- Problem Depiction

Engine 125CC ( BS -6 ) Crankcase right Machining at new aluminum phase Washing at engine assembly

Rejected crankcase Crankshaft pressing with crankcase Bearing and crankcase fitment Supply at material feeding conveyor

Conclusion :- Crankcase rejection during crankshaft pressing

Title: Elimination Of Right Crankcase rejection of 125 cc model at

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Step -3 Define the problem 3.7:- Problem effect

Getting irritation
All man hours idle
Conveyor Required additional manpower
Due to line
stoppage
stoppage
Other work affected
Right crankcase rejection

Production loss

Internal customer Productivity effect

Machine waiting for
breakdown crankcase Addition manpower for rework
assembly
Extra space required for stocking of
rejected crankcase

Chances of accident

Right Crankcase Rejection cost Department mission & vision affected

damage increasing
Chances of defect generation

Title: Elimination Of Right Crankcase rejection of 125 cc model at

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Step -3 Define the problem 3.6:- Process flow

START Problem Area END

VENDOR DRAIN BOLT AND

REJECTION AREA BEARING PRESSING DISPATCH
(SUNBEAM) NIPPLE PRESSING

NO
PRODUCT ENTRY Yes DIMENSIONS BINNING AND SUPPLY
(STORE) SUB ASSEMBLY CO TESTING
OK? TO SUB ASSEMBLY

BOLT STUD FITTING &

SAMPLING INSPECTION CHECKING BY VENDOR WASHING AT ENGINE
SUPPLY TO CRANKSHAFT ASSEMBLY WITH FRAME
(B.O.I) PERSONS ASSEMBLY
PRESS MACHINE

DIMENSIONS NO STORE REJECTION MOVES TO ENGINE CRANKSHAFT ASSEMBLY

AUDITING /SCANNING
OK? AREA ASSEMBLY WITH RIGHT CRANKCASE
YES YES
NO CRANKCASE NO
STORE AREA CRANKCASE OK ? ENGINE OIL FILLING
OK?

YES
PPC prepares Material
SCRAP WASHING & CHECKING ASSEMBLY AT OFF LINE
Pick Up Note (MPN) ENGINE LEAKAGE TESTING
AT QUALITY GATE CONVEYOR
in SAP system

SUPLY TO LOADING ON ASSEMBLY AT

MACHINING
NEW ALUMINUM PHASE MARSHAL CONVEYOR MAIN CONVEYOR

Conclusion :- We observed that problem generating at crankshaft press machine and persisting at inspection stage .
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 23
Step -3 Define the problem 3.3:- Problem Depiction
Crankshaft press SPM Process flow diagram of crankshaft shaft assembly with right crankcase

START End

Press switch on & Assembly at off line

Start the machine conveyor

OK
Scrap Right
Taking right crankcase from N.G crankcase
sub assembly assembly ok
?

Right crankcase fitment Remove the right crankcase

on fixture After crankshaft assembly

Crankshaft fitment on
fixture Crankshaft pressing

OPERATION
Press the cycle button Crankcase declamping

Crankshaft moving forward

Clamping the right
For fitment with right
crankcase
crankcase

Problematic area
Crankshaft pressing with right crankcase
Conclusion :- We observed that problem generating at crankcase fitment on fixture ,clamping and crankcase declamping and persisting at
crankcase inspection after crankshaft pressing with crankcase
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 24
Step -3 Define the problem 3.7:- Objective & Target Setting
Using ‘SMART’ Technique
INCREASE IN INTERNAL STRAIGHT PASS

(FROM 95% TO 96%) Right crankcase 125 CC Rejection To Be

INCREASE IN EXTERNAL STRAIGHT PASS Eliminate From Average 31 Nos. per

(FROM 96% TO 97%) Month 00 Month By 11 th March 2021”

REDUCTION IN REJECTION AND REWORK COST

(COST INCREASE FROM RS.12679 / MONTH)

Present situation 31 Crankcase /month
REDUCTION IN ADDITIONAL MAN POWER COST

(REDUCTION BY Rs. 9600 / Yr) Good Gap 31 Crankcase /month

TO BE A HEALTHY WORKING ENVIORNMENT

Ideal situation
GOOD QUALITY OF ENGINE 0 Crankcase /month

Objective was decided on the basis of ‘Voice of Goal decided base on data received from
Customer’, what customer wants the most and can be system

delighted from achieving the goal set for the project.

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 25
Step 4: Analyzing The Factors 4.1:- Stratification of data
Classification of internal rejection
Average data of September 20 ~ November-20
ENGINE PRODUCTION MONTH WISE TOTAL COMPONENT REJECTION AT ENGINE ASSEMBLY
150000 124032 3000
111940 108838 185
90542

In Nos.
2000 175
In Nos.

100000 162 176

Good
2043
1000 1644
50000 1441 1443

0
0
Sep-20 Oct-20 Nov-20 Average
Sep-20 Oct-20 Nov-20 Average
PPM NOS.
74 COMPONENT REJECTION AT ENGINE ASSEMBLY DEPARTMENT WISE REJECTION CONTRIBUTION
100.00
95.95 100
80 74
70 89.19

60 77.03
80
70
50 62.16
60

In Nos.
In Nos.

60
50
40
35

Good
30
41.89
40
40
Comm. %age

30 23
20 18 15
31 20 20 10
10
15
11 9 5 3 10
0 0
Right
crankcase
ACG
Rejection
Lef t and right Cy linder head
crankcase surf ace ng.
Cy linder
broken
Crank shaft
thread ng.
0
rejection in
125cc model
surf ace
up/ down
Engine Steel Heat Old Al New Al BOI
Assy. phase treatment Phase Phase

Conclusion :- After analysis the problem Crankcase broken is the highest contributing .
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 26
Step 4: Analyzing The Factors 4.2:- Stratification of data
Rejection data of September 2020

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 27
Step 4: Analyzing The Factors 4.2:- Stratification of data
Rejection data of September 2020

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 28
Step 4: Analyzing The Factors 4.2:- Stratification of data
Rejection data of November 2020

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 29
Step 4: Analyzing The Factors 4.2:- Stratification of data
Right crankcase rejection 125CC
3

WHEN ? 2 2 2
2

In Nos.
1 1 1 1
1

0 0 0 0 0
0
14.12.2 020 15.12.2 020 16.12.2 020 17.12.2 020 18.12.2 020 19.12.2 020 21.12.2 020 22.12.2 020 23.12.2 020 24.12.2 020 25.12.2 020 26.12.2 020

RIGHT CRANKCASE REJECTION

Right crankcase Monetary impact ( In Rupees )

Date Production Man Hour Loss
rejection Rejection losses Man hour losses Total
14.12.2020 4367 2 2 818 300 1118
15.12.2020 4320 1 1 409 150 559
16.12.2020 3650 0 0 0 0 0
17.12.2020 4768 1 1 409 150 559
18.12.2020 4472 2 2 818 300 1118
19.12.2020 4531 0 0 0 0 0
21.12.2020 4528 2 2 818 300 1118
22.12.2020 4334 0 0 0 0 0
23.12.2020 4642 1 1 409 150 559
24.12.2020 4780 0 0 0 0 0
25.12.2020 4504 1 1 409 150 559
26.12.2020 4286 0 0 0 0 0
Total 4431 10 10 4090 1500 5590

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 30
Step 4: Analyzing The Factors 4.3:- Stratification of data
Right crankcase rejection BS-6 (125cc model)
3

WHERE ?

In Nos.
2
1 1 1 1 1 1 1 1
1 1 1
0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
14.12.2020 15.12.2020 16.12.2020 17.12.2020 18.12.2020 19.12.2020 21.12.2020 22.12.2020 23.12.2020 24.12.2020 25.12.2020 26.12.2020
Crankcase fitment at fixture Crankcase clamping system Crankcase declamping system
DATE PRODUCTION shift Crankcase fitment at fixture Crankcase clamping system De clamping of right crankcase TOTAL
A 0 0 0 0
14.12.2020 4367
B 1 0 0 1
A 1 0 0 1
15.12.2020 4320
B 0 0 0 0
A 0 0 0 0
16.12.2020 3650
B 0 1 0 1
A 0 1 0 1
17.12.2020 4768
B 0 0 0 0
A 0 0 1 1
18.12.2020 4472
B 0 0 0 0
A 0 0 0 0
19.12.2020 4531
B 0 0 0 0
A 1 0 0 1
21.12.2020 4528
B 0 0 0 0
A 0 0 0 0
22.12.2020 4334
B 0 1 0 1
A 1 0 0 1
23.12.2020 4642
B 0 0 0 0
A 0 0 0 0
24.12.2020 4780
B 0 0 1 1
A 0 0 0 0
25.12.2020 4504
B 1 0 0 1
A 0 0 0 0
26.12.2020 4286
B 0 0 0 0
Total 4431 5 3 2 10

WHO ? Concerned system process of crankshaft pressing in crankcase right

Conclusion :- Areas where problem found
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 31
Step 4: Analyzing The Factors 4.4:- Stratification of data

Reason for Right Crankcase Rejection (125CC)

HOW 6
5
5

MUCH ? 4

In Nos.
3
3 2
2
1 0 0 0 0 0 0
0
Crankcase loading Rough locator Crankcase Crankshaft Assembly Crankcase Resting pad Ram length Guide bush
clamping system pressing process operator declamping
system

14.12.20 15.12.20 16.12.20 17.12.20 18.12.20 19.12.20 21.12.20 22.12.20 23.12.20 24.12.20 25.12.20 26.12.20
Da te and shift TOTAL
Reason A B A B A B A B A B A B A B A B A B A B A B A B

Crankcase loading 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Rough locator 0 1 1 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0 0 0 0 1 0 0 5

Crankcase clamping system 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 3

Crankshaft pressing process 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Assembly operator 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Crankcase declamping system 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 2

Resting pad 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Guide bush 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Ram length 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Total 0 1 1 0 0 1 1 0 1 0 0 0 1 0 0 1 1 0 0 1 0 1 0 0 10

Conclusion :-Reasons for problem occurring were highlighted.

Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 33
Step 5: Identification of causes 5.1 List of probable causes
Sl No. Probable causes Sl No. Probable causes

1 Education (illiterate/insufficient) 17 Side rail ( ram length )

2 Experience (work /Job) 18 Fixture main base (MTG bracket)

3 Awareness (knowledge /Behaviour) 19 LVDT slide unit

4 Knowledge (machine /product) 20 Cylinder nose (connecting plate)

5 Efficiency (skill /work speed ) 21 Stopper plate (side plate design)

6 Shaft fixture unit 22 Crankcase loading on fixture (machine operator)

7 Crankshaft fixture (resting plate ) 23 Work in hurry

8 V block (sensor plate angle) 24 Negligence

9 Main bracket (locator design ) 25 Production pressure

10 Plate for fixture base ( fixture packing) 26 Crankshaft pressing (procedure )

11 Case fixture unit

27 Crankcase declamping process

12 Clamp arm (design /position ) 28 Crankcase declamping before crankshaft press

13 Rough locator (design /size) 29 Procedure

14 Fixed slide base (resting pad ) 30 Right crankcase (profile/hardness)

15 Guide bush (design / position ) 31 Air pressure (less/more )

16 HYD pressing slide unit 32 Hydraulic pressure (less/more )

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 34
Step 5: Identification of causes 5.2 Classification of probable causes
MAN MACHINE METHOD MATERIAL

Crankcase loading on fixture (machine

Education (illiterate/insufficient) Shaft fixture unit Right crankcase (profile/hardness)
operator)

Experience (work /Job) Crankshaft fixture (resting plate ) Work in hurry Air pressure (less/more )

Awareness (knowledge /Behaviour) V block (sensor plate angle) Negligence Hydraulic pressure (less/more )

Knowledge (machine /product) Main bracket (locator design ) Production pressure

Efficiency (skill /work speed ) Plate for fixture base ( fixture packing) Crankshaft pressing (procedure )

Case fixture unit Crankcase declamping process

Crankcase declamping before

Clamp arm (design /position )
crankshaft press

Rough locator (design /size) Procedure

Fixed slide base (resting pad )

Guide bush (design / position )

HYD pressing slide unit

Side rail ( ram length )

Fixture main base (MTG bracket)

LVDT slide unit

Cylinder nose (connecting plate)

Stopper plate (side plate design)

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 35
Step 5: Identification of causes 5.3 Cause and effect diagram
MAN MACHINE
Crank shaft fixture
Insufficient Skill
Plate for fixture base
Design
Semiskilled Unskilled Side rail Fixture packing
Education Resting plate
Efficiency Ram length
Illiterate Shaft fixture unit
Design
Work Slow/fast Hydraulic pressing slide unit Locator Sensor plate angle
Less /New Work speed Main bracket
Experience Machine
Mtg bracket V-block
Fixed slide base Clamp arm
Less /New Less /No Fixture main base
Job Hard bush Design
Knowledge Design /hardness Cylinder nose
Behavior Position
Resting pad
Tension Less /No Connecting plate Case fixture unit
Habit Product LVDT slide unit Design Design
Size Position
Awareness Side plate
Rough Guide bush
Knowledge Design Stopper plate locator Right
Crankcase
Machine operator Rejection 125cc
Less Work in hurry
Production pressure
Hydraulic pressure Negligence
Crankcase loading on
More fixture
Less
Profile Procedure
Air pressure Crankshaft pressing
Right crankcase
Crankcase declamping before crankshaft press
More
Programming
Hardness Crankcase declamping process

MATERIAL METHOD

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 36
Step 6.0: Finding out root causes 6.1 identification of root causes
METHOD OF Time /Qty DEFECT DATA WITH DATE OF JAN 21
CAUSE PHENOMENA OBSERVATION APPROACH checked CAUSE TYPE
22/1 23/1 24/1 25/1 27/1 28/1

Education (insufficient/illiterate) Maximum operators are ITI Recruitment cell once 0 0 0 0 0 0 Not related
Experience (work /Job) Minimum one year Recruitment cell once 0 0 0 0 0 0 Not related
Output
MAN
Awareness (knowledge /Behaviour) Working easily on working stations performance
03 times in a day 0 0 0 0 0 0 Not related

They have well knowledge of Output

Knowledge (machine /product) machine and process performance
03 times in a day 0 0 0 0 0 0 Not related

Efficiency (skill /work speed ) No abnormality found in skill level Skill level test Daily 0 0 0 0 0 0 Not related
Crankshaft fixture (resting plate ) Design As per specification Drawing /manual Once in a week 0 0 0 0 0 0 Not related

Shaft V block (sensor plate angle) Design As per specification Drawing /manual Once in a week 0 0 0 0 0 0 Not related
fixture Main bracket (locator design ) Design As per specification Drawing /manual Once in a week 0 0 0 0 0 0 Not related
unit
Plate for fixture base ( fixture
packing) Design As per specification Drawing /manual Once in a week 0 0 0 0 0 0 Not related

02 times in a
Clamp arm (design /position ) Left side arm Position ng Visual inspection shift 0 1 0 2 0 0 Related

Case Worn out Visual inspection

02 times in a
Related
fixture Rough locator (design /size) shift 1 0 1 0 2 0
Machine
unit
Fixed slide base (resting pad ) Found Ok As per specification Drawing /manual Once in a week 0 0 0 0 0 0 Not related

Guide bush (design / position ) Found Ok As per specification Drawing /manual Once in a week 0 0 0 0 0 0 Not related
HYD Side rail ( ram length ) Found Ok As per specification Drawing /manual Once in a week 0 0 0 0 0 0 Not related
pressing
slide Found Ok As per specification Drawing /manual Not related
unit Fixture main base (MTG bracket) Once in a week 0 0 0 0 0 0

LVDT Cylinder nose (connecting plate) Found Ok As per specification Drawing /manual Once in a week 0 0 0 0 0 0 Not related
slide
unit Stopper plate (side plate design) Found Ok As per specification Drawing /manual Once in a week 0 0 0 0 0 0 Not related
Crankcase loading on fixture (machine
operator) Crankcase loading system found ok Visual inspection 03 times in a day 0 0 0 0 0 0 Not related

METHOD Crankshaft pressing (procedure ) Crankshaft pressing system found ok Visual inspection 03 times in a day 0 0 0 0 0 0 Not related
Crankcase declamping before
Crankcase declamping process crankshaft pressing Visual inspection 03 times in a day 0 0 1 0 0 0 Related

Right crankcase (profile/hardness) Found Ok As per specification Drawing Once in a week 0 0 0 0 0 0 Not related
MATERIAL Air pressure (less/more ) Found Ok (5~10 cm2) Air pressure gauge Daily 0 0 0 0 0 0 Not related
Hydraulic pressure (less/more ) Found Ok (80~100kgcm2 ) Pressure gauge Daily 0 0 0 0 0 0 Not related

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 37
Step 6.0: Finding out root causes 6.2 identification of root causes
MAN MACHINE
Crank shaft fixture
Insufficient Skill
Plate for fixture base
Design
Semiskilled Unskilled Side rail Fixture packing
Education Resting plate
Efficiency Ram length
Illiterate Shaft fixture unit
Design
Work Slow/fast Hydraulic pressing slide unit Locator Sensor plate angle
Less /New Work speed Main bracket
Experience Machine
Mtg bracket V-block
Fixed slide base Clamp arm
Less /New Less /No Fixture main base
Job Hard bush Design
Knowledge Design /hardness Cylinder nose
Behavior Position
Resting pad
Tension Less /No Connecting plate Case fixture unit
Habit Product LVDT slide unit Design Design
Size Position
Awareness Side plate
Rough Guide bush
Knowledge Design Stopper plate locator Right
Crankcase
Machine operator Rejection 125cc
Less Work in hurry
Production pressure
Hydraulic pressure Negligence
Crankcase loading on
More fixture
Less
Profile Procedure
Air pressure Crankshaft pressing
Right crankcase
Crankcase declamping before crankshaft press
More
Programming
Hardness Crankcase declamping process

MATERIAL METHOD

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 38
Step 6.0: Finding out root causes 6.3 Validation of possible cause-1
Velidation of possible cause -1 :- Rough locator
DATE :-29.01.2021 LINE :-2 MACHINE :- Crankshaft pressing TREND

Rough locator DESCRIPTION Right crankcase rejection

5000 4432 4520 4414 4532 5
4320
4023
What Crankcase rejection 4000 4

No. of defects
Production
3000 3
When During crankshaft pressing with
crankcase 2000 2
1 1 1
Who Rough locator 1000 1
0 0 0 0 1 0

Where At crankshaft pressing machine 0 0

22-01- 23-01- 24-01- 25-01- 26-01- 27-01- 28-01-
2021 2021 2021 2021 2021 2021 2021
How Crankcase does not resting properly PRODUCTION SHIFT A DEFECTS SHIFT B
on fixture during crankshaft pressing
Why-why analysis of possible Cause – 1
Why Right crankcase rejection due to rough locator ?
Related cause WHY -1 WHY -2 WHY -3 WHY -4 IDEA

Rough locator Crankcase falling during Crankcase does not Less length of rough Rough Locator design Rough locator design to
loading resting properly locator be change

ROOT CAUSE :-Rough locator design

Conclusion :- Rough locator design to be change .

Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 39
Step 6.0: Finding out root causes 6.4 Validation of possible cause-2
Velidation of possible cause -2 :- Clamping arm
DATE :-29.01.2021 LINE :-2 MACHINE :- Crankshaft pressing TREND

Clamping arm DESCRIPTION

Right crankcase rejection
5000 4432 4520 4414 4532 5
4320
What Crankcase rejection 4023

No. of defects
4000 4

Production
When During crankshaft pressing with
crankcase 3000 3

Who Left hand Clamping arm 2000 2

1 1
1000 1
Where At crankshaft pressing machine 0 0 0 1 0 0
0 0
How Left hand declamping before 22-01-202123-01-202124-01-202125-01-202126-01-202127-01-202128-01-2021
crankshaft press to avoid striking PRODUCTION SHIFT A DEFECTS SHIFT B
with fixture
Why-why analysis of possible Cause – 2
Why Right crankcase rejection due to clamping arm ?
Related cause WHY -1 WHY -2 WHY -3 WHY -4 IDEA

Clamping arm Crankcase falling during Clamp arm declamping To avoid striking with Left side Clamp position LH Clamp position to be
crankshaft pressing before crankshaft press fixture unit change

ROOT CAUSE :- left side clamp position

Conclusion :- left side clamp position to be change .

Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 40
Step 6.0: Finding out root causes 6.5 Validation of possible cause-3
Velidation of possible cause -3 :- Right crankcase declamping process
DATE :-29.01.2021 LINE -2 MACHINE :-Crankshaft pressing TREND

Crankcase declamping process DESCRIPTION

Right crankcase rejection
5000 4432 4520 4532 5
WHAT Right crankcase rejection 4320 4414
4023

No. of defects
4000 4
When During crankcase declamping

Production
3000 3
who Crankcase declamping process
2000 2
Where At crankshaft pressing machine 1
1000 1
0 0 1 0 0 0
How Crankcase declamping before
0 0
crankshaft inserting in crankcase thus 22-01-202123-01-202124-01-202125-01-202126-01-202127-01-202128-01-2021
crankcase falling during crankshaft PRODUCTION SHIFT A DEFECTS SHIFT B
pressing

Why-why analysis of possible Cause – 3

Why Right crankcase rejection due to crankcase declamping process ?
Related cause WHY -1 WHY -2 WHY -3 WHY -4 IDEA

Crankcase de clamping Crankcase falling during Crankcase declamping before Crankcase Declamping Declamping Crankcase declamping
process crankshaft pressing crankshaft insert in crankcase procedure at machine programming programming to be
change (Crankcase to be
de clamp after crankshaft
insert in crankcase )

ROOT CAUSE :-Crankcase declamping programming

Conclusion :- Crankcase declamping programming to be change (Crankcase to be de clamp after crankshaft insert in crankcase )
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 41
Step 7.0: Data Analysis

1 3
Rough locator design Crankcase declamping
programming

2
Left side clamp position

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 42
Step 7.0: Data Analysis of root cause 7.1 Analysis of root cause
Verification of Root Cause -1
Root cause Analysis How Who Remarks
Rough locator design We observed that right crankcase does Visual
not resting in fixture and frequent falling inspection and
during crankshaft pressing due to rough crankcase
locator less length rejection data

Quantity Defective
Date Shift Remarks
checked Quantity

A 525 0
29-01-2021
B 675 0
A 810 1
30-01-2021
B 745 0
A 625 0
01-02-2021 Rough locator does
B 495 1 not resting properly
A 575 0 in crankcase due to
02-02-2021 less length
B 620 0
A 711 0
03-02-2021
B 815 1
A 675 0
04-02-2021
B 725 0

Conclusion :- Rough locator design is the reason for defect generation.

Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 43
Step 7.0: Data Analysis of root cause 7.2 Analysis of root cause
Verification of Root Cause -2
Root cause Analysis How Who Remarks
LH Clamp position We observed that left side clamping arm Visual inspection
declamping before crankcase assembly and crankcase
with crankshaft to avoid striking with rejection data
fixture unit

Quantity Defective
Date Shift Remarks
checked Quantity

A 525 1
29-01-2021
B 675 0
A 810 0
30-01-2021
B 745 0
A 625 0
01-02-2021 Left hand
B 495 0 clamp arm
A 575 0 position
02-02-2021 wrong
B 620 1
A 711 0
03-02-2021
B 815 0
A 675 0
04-02-2021
B 725 0

Conclusion :- left hand clamping arm position is the reason for defect generation.
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 44
Step 7.0: Data Analysis of root cause 7.3 Analysis of root cause
Verification of Root Cause -3
Root cause Analysis How Who Remarks
Crankcase We observed that right crankcase falling Visual
declamping during crankshaft pressing because inspection
programming crankcase declamping before crankshaft and rejection
insert inside right crankcase data

Quantity
Date Shift Defective Quantity Remarks
checked

A 525 0
29-01-2021
B 675 0

A 810 0
30-01-2021
B 745 1

A 625 0
01-02-2021
B 495 0 Crankcase declamping
A 575 0 programming not ok
02-02-2021
B 620 0

A 711 0
03-02-2021
B 815 0

A 675 0
04-02-2021
B 725 0

Conclusion :- Crankcase declamping programming is the reason for defect generation .

Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 45
Step 7.0: Data Analysis of root cause 7.4 list of root causes
CONTRIBUTION
SL NO. ROOT CAUSE EFFECT (IN NOS.)
(%AGE)

1 Rough locator design 3 50

2 Left hand clamp position 2 33.34

3 Crankcase declamping programming 1 16.66

1, 17%

3, 50%
2, 33%

Rough locator design Left hand clamp position Crankcase declamping programming

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 46
Step 8.0: Developing the Solution 8.1 Solution Evaluation
CRITERIA

EFFECTIVENESS OF

PROBABILITY OF

RELATIVELY LOW
IMLEMENTATION

DEPT VISION &

HIGH RETURNS
THE SOLUTION
SL NO.

RESISTANCE
Total

EASE OF
ROOT CAUSE PROBABLE SOLUTIONS

SUCCESS

MISSION
Score

1 Modification ( U-cut) done in PU locator with 15mm

16
more length for better holding of crank case right

2 Steel (EN-8) locator with 15mm more length for

Rough locator design better holding of crank case right
30

3 Solid PU locator with 15mm more length provided for

20
better holding of crank case right

1 Left hand clamp position change 30

2 Modification in crank shaft holding fixture (10mm

Left hand clamp position 20
cut provided)

3 Change the double acting with 15mm less rod length 22

1 Shift the case fixture unit forward 22

2 Crankcase declamping programming to be change

Crankcase declamping (Crankcase to be de clamp after crankshaft insert in 30
programming crankcase )

3 Increase the stroke length by 15mm

24

WEA K RELA TIONSHIP (1) n MODERA TE RELA TIONSHIP (3)

STRONG RELA TIONSHIP (5)

Conclusion :- Individual probable solution was rated against the decided criteria based upon their criticality. The selection matrix depicted whether the Problem had STRONG,
MODERATE or WEAK relationship with the selected criteria.

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 47
Step 8.0: Developing the Solution 8.2 Solution Evaluation
Root Cause :- Rough locator design Trial period :- 05-02-21 to 06.02.21

BEFORE PROPOSED SOLUTION - 1 PROPOSED SOLUTION -2 PROPOSED SOLUTION -3

Modification ( U-cut) done in PU locator Solid PU locator with 15mm more Steel (EN-8) locator with 15mm more
Proposal with 15mm more length for better length provided for better holding of length for better holding of crank case
Selection criteria holding of crank case right crank case right right

Cost of implementation RS.257 2 RS .229 3 RS .623 2

Fulfilling department Yes 3 Yes 3 Yes 3
vision/mission
High return No 1 No 1 Yes 3
Sustainability No 1 No 1 Yes 3
Teams influence Low 1 Low 1 High 3
Safety issue No safety concern 3 No safety concern 3 No safety concern 3
Effectiveness Leg broken after 1525 cycle 1 Worn out after 3225 cycle 1 Ok working till now 3
Total score 12 13 20

Decision /Time line

Conclusion :- Steel (EN-8) rough locator with 15mm more length is selected for further implementation
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 48
(SCORE MARK CRITERIA-GOOD-3, FAIR-2, POOR-1)
Step 8.0: Developing the Solution 8.3 Solution Evaluation
Root Cause :- LH clamp position Trial period :- 08-02-21 to 09.02.21

BEFORE PROPOSED SOLUTION - 1 PROPOSED SOLUTION -2 PROPOSED SOLUTION -3

Modification in crank shaft holding fixture Change the double acting with 15mm Left hand clamp position change
Proposal (10mm cut provided) less rod length
Selection criteria
Cost of implementation RS 112 2 RS.3826 1 RS.235 2
Fulfilling department Yes 3 Yes 3 Yes 3
vision/mission
High return No 1 No 1 Yes 3
Sustainability No 1 No 1 Yes 3
Teams influence Low 1 Low 1 High 3
Safety issue No safety concern 3 No safety concern 3 No safety concern 3
Effectiveness No impact to avoid striking 1 Clamp Striking with 1 No possibility of clamp 3
crankcase striking
Total score 12 13 20

Decision /Time line

Conclusion :- Left hand clamping position to be change is selected for further implementation.
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 49
(SCORE MARK CRITERIA-GOOD-3, FAIR-2, POOR-1)
Step 8.0: Developing the Solution 8.4 Solution Evaluation
Root Cause :- Crankcase declamping programming Trial period :- 10-02-21 to 11.02.21

BEFORE PROPOSED SOLUTION - 1 PROPOSED SOLUTION -2 PROPOSED SOLUTION -3

Shift the case fixture unit forward Increase the stroke length by 15mm Crankcase declamping programming to
Proposal be change (Crankcase to be de clamp
Selection criteria after crankshaft insert in crankcase )

Cost of implementation - - -
Fulfilling department Yes 3 Yes 3 Yes 3
vision/mission
High return No 1 No 1 Yes 3
Sustainability No 1 No 1 Yes 3
Teams influence Low 1 Low 1 High 3
Safety issue Safety concern 1 No safety concern 3 No safety concern 3
Effectiveness Crankcase striking with 1 Production loss 1 No chances of crankcase 3
crankshaft rejection
Total score 8 10 18

Decision /Time line

Conclusion :- Crankcase declamping programming to be change is selected for further implementation

Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 50
Step 8.0: Developing the Solution 8.5 Solution Assessment

S.No What Where Why Who When How

For elimination of
With the
New designed right crankcase
At crankshaft Rajinder Up to 18-02- support of
1 steel (En-8) rough rejection during
pressing SPM singh 2021 engineering
locator crankshaft
department
pressing

For elimination of With the

right crankcase support of
Left side clamp At crankshaft Anand Up to 18-02-
2 rejection during engineering and
position change pressing SPM mohan 2021
crankcase maintenance
clamping department

Crankcase
declamping
programming to For elimination of With the
right crankcase support of
be change At crankshaft Up to 25-02-
3 rejection during Sahab singh engineering and
(Crankcase to be pressing SPM 2021
crankcase maintenance
de clamp after declamping department
crankshaft insert
in crankcase
Conclusion :- Responsibility given to each member for better solution Assessment
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 51
Step 9.0: Foreseeing probable resistance 9.1 Identification Of Resistance

Sl Resistance Resistance
Countermeasure planned Discussion
no. anticipated overcome

Production
Discussion with
engineering After discussion
production
New designed steel (En-8) rough department head they assured that
1 engineering
locator said that there may it will do as soon
department head
delay due to long as possible
about it
process

2 Left side clamp position change No resistance Nil Nil

Crankcase declamping programming

to be change (Crankcase to be de
3 No resistance Nil Nil
clamp after crankshaft insert in
crankcase

Conclusion : Resistance were overcome .

Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 53
Step 10 : Trial Implementation 10.1 New designed rough locator

P New designed steel (EN-8) rough locator

D
IMPLEMENTED ON
19th February 2021

Drawing of rough locator New designed rough locator Crankcase fitment on rough locator New locator fitment in crankcase

DATE PRODUCTION DEFECT Right crankcase model mix Effect Gain

8 Cause Solution Effect
9 % %
19-02-2021 4055 1 8
7
6
In nos.

Rough locator Rough locator design 14 45.16 45.16

21-02-2021 3316 0 5
4
C 22-02-2021 3675 1 3 Lef t hand clamp
2 Clamping arm 10 32.25
23-02-2021 3300 1 1 4 position

0
Crankcase
24-02-2021 3329 0 Before C/m data per After C/m 1 declamping
Crankcase declamping
7 22.59
week of September-20 programming
process
to November- 20 07.08.20 to 13.08.20
25-02-2021 2953 1 Total 31 100% 45.16

A New designed Steel (EN-8) locator provided with the help of Production engineering department.

Conclusion : Chances of crankcase falling during crankshaft pressing eliminates.

Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 54
Step 10 : Trial Implementation 10.2 Left side clamp position change

P Left side clamp position change

IMPLEMENTED ON
19th February 2021
Job order for maintenance Left hand Clamp position Right crankcase assembly on Crankshaft press machine
Right crankcase rejection
DATE PRODUCTION DEFECT 9 8 Cause Solution Effect
Effect Gain
8 % %
19-02-2021 4055 1 7
6
In nos.

Rough locator Rough locator design 14 45.16 45.16

21-02-2021 3316 0 5
4
C 22-02-2021 3675 0 3
Lef t hand clamp
2 Clamping arm 10 32.25 32.25
23-02-2021 3300 0 1
4 2
position

0 Crankcase
24-02-2021 3329 0 Before C/m data After C/m 1 After C/m 2 declamping
Crankcase declamping
7 22.59
per week of programming
process
September-20 to
25-02-2021 2953 1
November- 20 Total 31 100% 77.41

A Left side clamp position with the help of maintenance department

Conclusion : Chances of crankcase rejection due to left side clamp position eliminate
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 55
Step 10 : Trial Implementation 10.3 Crankshaft declamping programming change

Crankcase declamping programming to be change (Crankcase to be de clamp after

P
crankshaft insert in crankcase

IMPLEMENTED ON
25th February 2021

Crankcase declamp after crankcase insert Programming of crankcase declamping

Right crankcase rejection Effect Gain

DATE PRODUCTION DEFECT 10 Cause Solution Effect
8 % %
26.02.2021 3935 0 8
6
In nos.

Rough locator Rough locator design 14 45.16 45.16

27.02.2021 3415 0
4
C 01.03.2021 3212 0
2 Lef t hand clamp
4 0 Clamping arm
position
10 32.25 32.25
02.03.2021 3267 0
0
2
Before C/m After C/m 1 After C/m 2 After C/m 3 Crankcase
03.03.2021 3200 0 data per week declamping
Crankcase declamping
7 22.59 22.59
programming
of September- process
04.03.2021 3561 0 20 to
November- 20 Total 31 100% 100%

Crankcase declamping programming change with the help of maintenance department now crankcase declamp
A
after crankshaft insert in crankcase.

Conclusion : Chances of right crankcase rejection due to declamping programming eliminate .

Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 56
Step 11.Regular Implementation 11.1 Milestone Chart for Full Implementation

Specific
Person In
SL Countermeasure For Implementation
Item (What) Charge
NO. Implementation (By When)
(Who)
(How)

With the help of department

New designed steel (En-8) rough
1 Davinder head of production 05.03.2021
locator
engineering

With the help of department

2 Left side clamp position change Sahab singh 05.03.2021
head of engine assembly

Crankcase declamping
With the help of department
programming (Crankcase to be de head of engine assembly
3 Anand mohan 05.03.2021
clamp after crankshaft insert in
crankcase

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 57
Step 11 : Regular Implementation 11.2 Comparison Before & After
Data Tracking After implementation of countermeasures
Before Action Period After

35 33 32

30 28
* 25
Better
25
TARGET = 00
19 CRANKCASE/MONTH
20
100%
15
11
10

5
0 0 0 0 0 0 0 0
0 0 0 0 0
1 2 10 11

Months Days Of November-21

S no. Countermeasure

1 New designed steel (En-8) rough locator

2 Left side clamp position change
Crankcase declamping programming to be change (Crankcase to be de clamp after crankshaft
3
insert in crankcase
*Deacreased due to Temporary action taken
Title: Elimination Of Right Crankcase rejection of 125 cc model at
Internal - General crankshaft press machine 58
Step 11 : Regular Implementation 11.3 Benefits – Tangible

Right Crankcase Rejection 125cc BEFORE IMPLEMENTATION

34
32 33 Rejection in no.s MONETARY IMPACT (In Rs.)
32
30 31 Month Production Engine reworked Man hour loss Rejection Losses Man hr. Losses Total
28
28 Sep-20 111940 33 16 13497 1600 15097
26
24
Oct-20 124032 32 16 13088 1600 14688
Sep-20 Oct-20 Nov-20 Average Nov-20 90542 28 8 11452 800 12252
Current Si tuation 31 Engines /Month
Average 108838 31 13 12679 1333 14012

Ga p 31 Cra nkcase /month

AFTER IMPLEMENTATION
Rejection in no.s MONETARY IMPACT (In Rs.)
Ideal Situation 00 engine /month
Month Production Engine reworked Man hour loss Rejection Losses Man hr. Losses Total
33
Right crankcase rejection BS-6 125 cc Dec-20 86971 25 16 10225 1600 11825
35 32
30
28
25
Jan-21 111235 19 16 7771 1600 9371
NO. OF DEFECTS

25 19 Feb-21 92543 11 8 4499 800 5299

20
15 11 Til now 32450 0 0 0 0 0
10
Expenses for implementation about Rs. 3500 this is the one time investment
5 0
0 Yearly Saving After Implementation of Project Rs. 14012 x12=
Sep-20 Oct-20 Nov-20 Dec-20 Jan-21 Feb-21 Till now
Rs.168144

Title: Elimination Of Right Crankcase rejection of 125 cc model at

Internal - General crankshaft press machine 59
Step 11 : Regular Implementation 11.4 Benefits – Intangible

Radar graph to see how skillful

THEME CAUSE RESULT RESULT improvement among members has been
IMPLEMENTA
SELECTION ANALYSIS TION ANALYSIS ANALYSIS Inquiry skill
TEAM PROGRESS 10

Team skill 8 Planning skill

6
100.00

4
96.19 100
100 89.52

Facilitating skill Probing skill

90 80.95
80
80
67.62
70

2
60
60
50.48

50

40
40
29.52
30

0
20 20
31
10 22
18
14
9 7 4
0 0
Right Kick noise Left and right Engine jerking Engine neutral Kick No start of
crankcase crankcase drive movement vehicle
rejection in surface free
125cc model up/down

Logical skill Analytical thinking

TEAM DYNAMIC
(OUTPUT) CURVE
Coordinating skill Systematic thinking
SHARPENED SKILLS Analytical Facilitating skills
Inquiry skill Probing skill Coordinating
thinking
skill Aligning skill
Planning skill Analytical Planning skill Logical skill
thinking Before After

Aligning Skill
Systematic thinking / Conceptual skill
Remarks: Based on individual’s evaluation (1-10 points)

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Step 11 : Regular Implementation 11.5 Feed back

SO THAT THIS PROBLEM DOES NOT RE – OCCUR ,

WE HAVE GIVEN FEED BACK TO FOLLOWING
CONCERNED DEPARTMENTS & PERSONS

1. ALL ENGINE ASSEMBLY OPERATORS

2. PRODUCTION ENGINEERING & MAINTENANCE DEPARTMENT
3. HEAD OF DEPARTMENT ENGINE ASSEMBLY
4. SPECIALLY TO RELATED OPERATOR
5. QUALITY ASSURANCE DEPARTMENT

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Step 12 : Follow up & Review 12.1 Need Based Check Sheet For Process Sustenance

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Step 12 : Follow up & Review 12.2 Standardization

STANDARDIZATION
Core team :- Sahab Singh,davinder Singh,amit
Part no. Latest change level :- Right crankcase rejection 125cc Saini,parvinder Singh,anand Mohan, Rajinder Date :-05.03.2021
Surender Kumar
Part name /description :-Right
crankcase 125cc BS-6 Method
Characteristics
Sample
CTQ? Reaction plan
Problem specific Evaluation/ Control
Proces s Machine process measurement method
Process/part name Product Process Qty. Frequency
number device

Rough
Cra nks haft Cra nks haft Ma chi ne s top and
New designed steel Ri ght Ri ght cra nkcase damage Rough l ocator l oca tor
1 pres s pres sing with Yes 1245 Twi ce i n a s hift ha ve to ca ll
(En-8) rough locator cra nkcase 125cc l ength l ess des ign
ma chine cra nkcase ma i ntenance
cha nge

Left ha nd
Cra nks haft Cra nks haft Cl a mp striking cl a mp Ma chi ne s top and
Left s i de clamp Ri ght Ri ght cra nkcase damage
2 pres s pres sing with Yes wi th fi xture 1325 Twi ce i n a s hift pos ition ha ve to ca ll
pos ition change cra nkcase 125cc
ma chine cra nkcase uni t cha nge ma i ntenance

Cra nkcase
decl amping Cra nkcase
progra mming Cra nks haft Cra nks haft decl amping Decl amping Ma chi ne s top and
Ri ght Ri ght cra nkcase damage
3 cha nge (Cra nkcase pres s pres sing with Yes before 1325 Twi ce i n a s hift progra m ha ve to ca ll
cra nkcase 125cc
to be de clamp a fter ma chine cra nkcase cra nkshaft cha nge ma i ntenance
cra nkshaft i nsert i n pres sing
cra nkcase

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Step 12 : Follow up & Review Step 12.3 : Mistake Proofing

Steel (EN-8) rough locator Steel (EN-8) rough locator insert in crankcase

Crankcase declamping programming change LH clamp position

(Crankcase to be de clamp after crankshaft
insert in crankcase

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Step 12 : Follow up & Review Step 12.4 : Milestone Chart After
QC NAME :- TECHIZ DEPARTMENT :- ENGINE ASSEMBLY H.O.D : RAKESH SHARMA COORDINATOR :- D.L SIDHWANI
PROJECT :- ELIMINATION OF RIGHT CRANKCASE REJECTION OF 125 CC AT CRANKSHAFT PRESS MACHINE
REASON FOR SELECTION :- DEFECT % INCREASING,TO DECREASE REJECTION COST, TO INCREASE STRAIGHT PASS, TO INCREASE PRODUCTIVITY
TARGET PERIOD TEAM
MEASUREMENT ITEM U.O.M FROM TO FROM TO LEADER DY. LEADER MEMBER FACILITATOR
REJECTION NOS. 31 0 11.12.2020 11.03.2021 PARVINDER SINGH AMIT SAINI DAVINDER ANAND MOHAN SAHAB SINGH RAJINDER SINGHSURENDER KUMAR

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65
PLANT SHUTDOWN FROM 27 DEC 20 TO 04 JAN 21
Step 12 : Follow up & Review Step 12.4 : Milestone Chart After

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66
PLANT SHUTDOWN FROM 27 DEC 20 TO 04 JAN 21
Step 12 : Follow up & Review Step 12.4 : Milestone Chart After

Person In Specific
SL Implementation
Item (What) Charge Countermeasure For Actual
NO. (By When)
(Who) Implementation (How)

With the help of

New designed steel (En-8)
1 Davinder department head of 05.03.2021 05.03.2021
rough locator
production engineering

With the help of

Left side clamp position
2 Sahab singh department head of 05.03.2021 05.03.2021
change
engine assembly

Crankcase declamping
With the help of
programming (Crankcase to Anand
3 department head of 05.03.2021 05.03.2021
be de clamp after crankshaft mohan
engine assembly
insert in crankcase

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Step 12 : Follow up & Review 12.5 : Appreciation

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Step 12 : Follow up & Review 12.5 : Appreciation

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Step 12 : Follow up & Review Step 12.6 Qc tool & Technique Used

TOOLS /TECHINIQUES

CAUSE AND EFFECT DIAGRAM

MATRIX DATA ANALYSIS

WHY WHY ANALYSIS
BRAIN STORMING
FLOW DIAGRAM

PARETO CHART

ABC ANALYSIS
CHECK SHEET
Sl no

GRAPHS
PROBLEM SOLVING STEPS
1 IDENTIFICATION OF WORK RELATED PROBLEMS

2 SELECTION OF PROBLEMS

3 DEFINE THE PROBLEMS

4 ANALYSE THE PROBLEMS

5 IDENTIFICATION OF CAUSES

6 FINDING THE ROOT CAUSES

7 DATA ANALYSIS

8 DEVELOPING THE SOLUTION

9 FORESEEING THE PROBABLE RESISTANCE

10 TRIAL IMPLIMENTATION

11 REGULAR IMPLEMENTATION

12 FOLLOW UP/REVIEW

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Step 12 : Follow up & Review Step 12.7 : Summary of project
SUMMARY SHEET
HERO MOTOCORP. LTD .
DHARUHERA PLANT CATEGORY: QCC

PROJECT / THEME :- Elimination of Right crankcase PROJECT STARTED : 11.12.2020

rejection in 125cc model
PROJECT COMPLETED : 11.03.2021

PROBLEM / PRESENT STATUS : COUNTERMEASURES / AFTER IMPROVEMENT :

100.00
96.19 100
100 89.52

90 80.95
80
80
67.62
70
60
60
50.48

50

40
40
29.52
30

20 20
31
10 22
18
14
9 7 4
0 0
Right K i ck n o i se L eft an d En g i n e En g i n e K i ck N o star t o f
cr an kcase right j er ki n g n eu tr al mo vemen t veh i cl e
r ej ecti o n i n cr an kcase d r i ve fr ee
125cc su r face
mo d el u p / d o wn

ANALYSIS : RESULTS :

Rough locator length less Rejection in no.s MONETARY IMPACT (In Rs.)
Month Production Engine reworked Man hour loss Rejection Losses Man hr. Losses Total
Left hand clamp position wrong
Dec-20 86971 25 16 10225 1600 11825
Crankcase declamping programming
Jan-21 111235 19 16 7771 1600 9371
Feb-21 92543 11 8 4499 800 5299
Till now 32450 0 0 0 0 0
BENEFITS: RIGHT CRANKCASE REJECTION125 CC FROM 31 NOS. TO ZERO
TEAM MEMBERS : - SAHAB SINGH,DAVINDER SINGH,ANAND MOHAN PREVENTION SHUT DOWN
IF IT IS MISTAKE PROOFING / POKE-YOKE,
,AMIT SAINI,PARVINDER SINGH, RAJINDER SINGH, SURENDER KUMAR
WHAT TYPE AND FUNCTION: DETECTION WARNING

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Step 12 : Follow up & Review Step 12.8 : Change in Documents

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Step 12 : Follow up & Review Step 12.8 : Change in Documents

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Step 12 : Follow up & Review Step 12.8 : Change in Documents

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Step 12 : Follow up & Review Step 12.8 : Change in Documents

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Step 12 : Follow up & Review Step 12.8 : Change in Documents

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Step 12 : Follow up & Review Step 12.8 : Change in Documents

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Step 12 : Follow up & Review Step 12.8 : Change in Documents

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Conclusion Lesson learnt

• Elimination of Defects improves core process, ultimately better performance

at Customer end

• Systematic problem solving approach is the key to success.

• Working in a Team gives better results.

• Team motivated, Skill developed.

• Study helps to understand process in deep, which increases Analytical Ability

and ultimately Confidence Building

• Learnt how not following proper schedule may damage process and
machinery .

• Learning of New Tools.

• Innovation comes after in depth analysis.

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Conclusion Slogan

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Conclusion Next Theme

NEXT THEME

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Conclusion Next Theme
QC NAME :- TECHIZ DEPARTMENT :- ENGINE ASSEMBLY H.O.D : RAKESH SHARMA COORDINATOR :- D.L SIDHWANI
PROJECT :- ELIMINATION OF GEAR SHIFTING HARD IN BS-6 125CC MODEL
REASON FOR SELECTION :- DEFECT % INCREASING,TO DECREASE REJECTION COST, TO INCREASE STRAIGHT PASS, TO INCREASE PRODUCTIVITY
TARGET PERIOD TEAM
MEASUREMENT ITEM U.O.M FROM TO FROM TO LEADER DY. LEADER MEMBER FACILITATOR
REJECTION NOS. 41 0 18.03.2021 11.06.2021 PARVINDER SINGH AMIT SAINI DAVINDER ANAND MOHAN SAHAB SINGH RAJINDER SINGHSURENDER KUMAR

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Conclusion Next Theme

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Conclusion

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Step 10 : Trial Implementation 10.3 Crankshaft declamping programming change

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