Internship Week-6

AADITYA

19070125001

MECHANICAL ENGINEERING

Faculty Mentor
Week Week
Weekly progress (to be entered by student) remarks and
No. Dates
suggestions

Week 30/01/23

6 Mon ZERO DEFECTS

&

31/02/23

Tue

01/02/23

Wed ESCORT STANDARD OPERATION SHEET

&

02/02/23
Thu
 03/02/23

Fri

& TOP DEFECTS IN ALL AREAS

04/02/23
Sat

05/02/23

Sun HOLIDAY

SUMMARY OF THE WEEK

ZERO DEFECT
Zero defects is a concept that can be viewed as a quest of perfection to improve quality at minimum Cost possible. A defect can be defined as a
non-conformance of a quality characteristic to its required specification. Thus, leading to waste which in return increases its cost of poor quality.
Zero defects is a concept to ensure that ‘there is no waste existing in a project’. The idea of Zero defects can be explained as that every
employee should "do things right the first time".

Theory ensures that there is no waste existing in a project. Waste refers to all unproductive processes, tools, and employees and so on.
Anything that is unproductive and does not add value to a project should be eliminated, called the process of elimination of waste.
Eliminating waste creates a process of improvement and correspondingly lowers costs.
 Take into consideration your customers’ expectations of quality: While it’s essential to create systems that support zero defects
where appropriate, don't over-compensate if it’s not important to the end-user.

 Build quality into performance expectations: Give your staff the incentive to think of ways to achieve zero defects, by rewarding
them when they're successful.

 Learn (and embrace) POKA-YOKE: Invented over half a century ago by a Shigeo Shingo, a Japanese industrial engineer, "poka-
yoke" (pronounced “POH-kay YOH-kay”) translates to "prevent inadvertent mistakes." Poke-yoke focuses on creating systems
that make mistakes almost impossible or, if they're unavoidable, at least easier to find and correct.

 Make continuous improvement and efficiency a high priority: If you want zero defects, you need to take a proactive approach.
This approach means that every member of all your teams are always testing how robust their favored processes are and
continually exploring ways to improve them and make them more efficient. Encourage your people to do this by introducing the
zero defects philosophy into your organization’s corporate culture. This introduction ensures that it the philosophy becomes an
accepted, default standard that staff will proactively work toward.

 Measure your quality efforts: It's vital that you express your team’s progress by means of the bottom line. Generate baseline
measurements so you can get a good idea about the cost of defects in your company and can subsequently quantify the benefits
you're gaining by addressing them.

ESCORT STANDARD OPERATION SHEET

1. Firstly, installation Drawing is obtained from the design department which provides 3D drawing to
Manufacturing engineering department (ME) for the part or component with material of the part /BOM.
2. After getting the Installation drawing by the ME for any Tractor model they open the drawing in Team centre
software which provide a real view for the part or component to ME person who is working on it.
3. Now staging for the model is made by ME which indicate the BOM for the tractor with figure and stage at
which part fitment/assembly take place.
4. As per staging the tractor is made on line/offline it totally depends on the model of tractor.
5. ME makes the SOP/Control Plan for each part fitment/assembly as per staging or line in predescribed format by
the company.

6 ME Provides the necessary tools and parts with co-ordination of store department .ME also available on line while
taking a new model tractor for smooth flow of all fitment/assembly of parts.

7. Now control plan is share with Production department which makes ESOS (Escorts Standard Operation Sheet
from that control plan as per tractor model, fitment and line for the easy understanding for operator.

8. ESOS provide the complete detail to operator to assemble/fit the part at their required place with all tools for
operation.

9. Through ESOS training is given to operator for the operation on line /offline for making a complete Tractor.
Top defects
As we discussed earlier there are three main stages of the assembly line – Before paint which has 4 quality gates,
Paint shop, and after paint which also includes 4 quality gates. So, I categorized all the defects in these three sections
and started working accordingly.

 Top defects of After-paint:

1. Radiator coolant does not fill/less.

2. Centre Panel alignment not set.
3. PTO shaft cap loose
4. Fender harness not set properly/ clamp not set.
5. Top link not set.
6. Plough lamp bolt loose/miss
7. Cluster meter beading not set.
8. RPM not set.
9. Bonnet alignment not set.
10. Running board wire without clamp
11. Steering wheel cap miss

 Top defects of Paint Shop:

1. Fender paint (poor/scratch/uncover/overflow)

2. Bonnet front grill paint
3. Rod box assembly paint
4. Poor Stay-bar finishing
5. Top link paint uncovers / overflow.

 Top defects of Before Paint:

1. Hydraulic Pressure pipe clamp loose/miss

2. Lower link height uneven
3. Spool valve banjo loose
4. Running bolt loose
5. Tow hook bolt loose/miss
6. Hydraulic adapter bracket bolt loose
7. Rod box assembly nipple broken.
8. Hydraulic pressure plate banjo loose
9. Fuel filter mtg. loose

These were the top defects that were coming continuously from the assembly line and due to which tractor is taking
more time to complete the stages of PDI which includes.
• Road Test
• Hydraulic dropping test
• UV test
• Road Test verification
• Rework
• Final Inspection
So, according to the data I inspected all the previous data of these defects and found 10 most common defects on
which I worked on and made action plans. So, the following defects are:

1. RPM not set.

2. Hydraulic pressure pipe clamp loose/miss
3. Alignment not set which includes:
Bonnet gap not set.
Centre-panel gap not set.
Top hood gap not set/overlap.
4. PTO shaft cap loose
5. Fender paint uncover/overflow/dusty/poor.
6. Cluster meter beading not set.
7. Lower link height uneven
8. Running board harness w/o clamp

Major defects:

1. Engine Overheating in field resulting into engine seizure

2. Main gear fouls with fender
3. Transmission noise
4. Bonnet gap
5. Fuel tank dent
6. Rear/Front tyres mismatch
7. Spindle & hub not greased
8. Fender tilted
9. Engine smoke
10. Brakes jam