PROJECT SEMESTER REPORT

(Jan 2023 – June 2023)

Submitted by :
Daksh Verma
102189003 3MEC2

Under the Guidance of:

Dr. Vineet Srivastava Mr. Tanaji Shinde

Mechanical Engineering Department Quality Department

TIET, Patiala MAHLE Anand Thermal

Systems, Pune

DEPARTMENT OF MECHANICAL ENGINEERING

THAPAR INSTITUTE OF ENGINEERING & TECHNOLOGY, PATIALA
(Declared as Deemed-to-be-University u/s 3 of the UGC Act, 1956)

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 Acknowledgement

I am grateful to the Almighty for the opportunity to complete this project semester without
any hindrance. This report is the product of hard work and the assistance of many people.
Without their help, this report would not have been possible.
I would like to express my deepest gratitude to my industry mentor, Mr. Tanaji Shinde, and
my faculty mentor, Dr. Vineet Srivastava. Their candid guidance, constructive suggestions,
and overwhelming inspiration have been invaluable to me. I am grateful for the opportunity
to have worked with such experienced and professional individuals. Their mentorship has
helped me to grow as a professional and has prepared me for a successful career in the field
of mechanical engineering.
I would also like to thank Mr. Rahul Hendre and Mr. Sagar Patil for providing me with the
facilities and guidance necessary to complete this work. Their support has been essential to
the success of this project.
Finally, I would like to thank my family for their support and encouragement. They have been
there for me every step of the way, and I could not have done this without them. Their love
and support have been a source of strength throughout this project.
I am confident that the knowledge and skills I have gained through this project will be
invaluable to me in my future career. I am grateful for the opportunity to have worked on this
project and for the support of all those who have helped me along the way.

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 Abstract

The projects that I undertook during the course of my internship at Mahle Anand Thermal
Systems were:

• Reduction of Scrap/Rework rate of Tube to Header (TTH) brazing problem in Z101

Condenser Model
• Design & Implementation of an ERM Coil Testing Device
• Develop the Old Visco clutch line Operational Documents (Process Improvement)

The goal of my First Project was to reduce the number of condensers that needed to be
reworked or scrapped after the full assembly process. This was a significant problem, as it was
both costly and time-consuming to repair or replace condensers. The specific problem I was
addressing was Tube-to-Header (TTH) leakage caused by improper brazing. TTH leakage is a
serious problem, as it can lead to the loss of refrigerant and the failure of the condenser. I
approached this problem by first conducting a root cause analysis to identify the factors that
were contributing to TTH leakage. Once I had identified the root causes, I developed a plan to
address them.

In my second project, I was tasked with designing and implementing a device that would be
used to test ERM coils. The device would check the resistance of the coil, verify that two
diodes in the coil are functioning properly, and determine if the hall sensor in the coil is
working correctly. I implemented the device using an Arduino microcontroller. This device
offers enhanced reliability, accuracy, and efficiency, catering to the specific needs of ERM coil
testing in a professional setting.

My third project was to update the company’s operational documents related to the Viscous
Clutch Fan line and EGR. The documents include PFDs (Process Flow Diagrams), Control Plans,
Product Parameter Sheets and Process Parameter Sheets.

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 List of Figures
Page No.

Figure 1 DMAIC ........................................................................................................................ 13

Figure 2 Exploded View of Z101 Condenser ............................................................................ 14
Figure 3 Fins ............................................................................................................................. 14
Figure 4 Tubes .......................................................................................................................... 15
Figure 5 TTH Leakage ............................................................................................................... 15
Figure 6 Fin Drop ...................................................................................................................... 16
Figure 7 Unbrazed Bracket....................................................................................................... 16
Figure 8 Baffle Leak .................................................................................................................. 16
Figure 9 TTH Position .............................................................................................................. 17
Figure 10 FTA Chart .................................................................................................................. 18
Figure 11 Points for marking TTH ............................................................................................ 18
Figure 12 Temperature Inside the Furnace ............................................................................. 19
Figure 13 Section View of Manifold ......................................................................................... 20
Figure 14 Insertion under Microscope..................................................................................... 20
Figure 15 ERM Coil ................................................................................................................... 25
Figure 16 Coil Internal Circuit .................................................................................................. 26
Figure 18 Coil Circuit ................................................................................................................ 27
Figure 17 Voltage Divider Circuit ............................................................................................. 27
Figure 19 Proposed Layout 1 ................................................................................................... 28
Figure 20 Proposed Layout 2 ................................................................................................... 29
Figure 21 Proposed Layout 3 ................................................................................................... 30
Figure 22 Final Layout Detailed ............................................................................................... 31
Figure 23 D1 not OK ................................................................................................................. 35
Figure 24 D2 not OK ................................................................................................................. 36
Figure 25 Proces Flow Bi-Metal ............................................................................................... 40
Figure 26 Process Flow E-Visco ................................................................................................ 41

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 List of Tables
Table 1 Size Comparison .......................................................................................................... 21
Table 2 Coil Test Parameters ................................................................................................... 25
Table 3 Components Cost Sheet .............................................................................................. 37
Table 4 Control Plan Sample .................................................................................................... 42
Table 5 Product Parameter Sample ......................................................................................... 43
Table 6 Process Parameter Sample ......................................................................................... 43

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 Table of Content
Page No.

Certificate 2

Declaration 3

Acknowledgement 4

Abstract 5

List of Figures 6

List of Tables 7

Chapter 1 – Company Overview 10

• Organization
• Company Portfolio
• Need Analysis
• Project Statement

Chapter 2 – Scrap/Rework Reduction for Condenser Model Z101 13

• Objective
• Introduction
• Prior Work
• Methodology
• Results
• Future Scope of Work

Chapter 3 – Design & Implementation of an ERM Coil Testing Device 24

• Objective
• Introduction
• Methodology
• Results
• Future Scope of Work

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Chapter 4 – Process Improvement for Viscous Clutch Fan Models 39

• Objective
• Introduction
• Prior Work
• Methodology
• Results

References 45

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 Chapter 1 – Organization

1. ORGANIZATION
MAHLE is a leading international development partner and a supplier to the automotive
industry as well as a driver of technology for the mobility of the future. The MAHLE Group
focuses on making transport more efficient, eco-friendly making it more comfortable.
Based on the competence of a broad system consisting of Engine Systems and
Components, Filtration, and Thermal Management, the group’s product portfolio
addresses all the crucial powertrain and air conditioning technology issues. MAHLE
products are fitted in at least every second vehicle worldwide. For decades, MAHLE
components and systems have also been used on the world’s racetracks and off the road
in stationary applications, for mobile machinery, rail transport, as well as marine
applications.

Date of Incorporation
Incorporated in 1997, MAHLE ANAND Thermal Systems came about as a result of ANAND’s
joint venture with MAHLE Behr GmbH & Co.KG, Germany.

Key Representative
Mr. Vinayak Hegde, Chief Operating Officer

Current Plant locations

Greater Noida, Chakan, MH Chennai, Tamil Nadu Ahmedabad, Gujrat

2. COMPANY PORTFOLIO
MAHLE is a leading international development partner and a supplier to the automotive
industry as well as a driver of technology for the mobility of the future. The MAHLE Group
focuses on making transport more efficient, eco-friendly making it more comfortable.
Based on the competence of a broad system consisting of Engine Systems and
Components, Filtration, and Thermal Management, the group’s product portfolio
addresses all the crucial powertrain and air conditioning technology issues. MAHLE
products are fitted in at least every second vehicle worldwide. For decades, MAHLE
components and systems have also been used on the world’s racetracks and off the road
in stationary applications, for mobile machinery, rail transport, as well as marine
applications.

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3. NEED ANALYSIS
The condenser is a heat exchanger in a car's air conditioning system. It is located in front
of the radiator and is responsible for cooling the refrigerant from a hot gas to a cool liquid.
The condenser is made up of a series of tubes and fins that allow the refrigerant to flow
through and cool down as it passes through the air.

The condenser works by transferring heat from the refrigerant to the air flowing through
it. The refrigerant is a gas when it leaves the compressor, and it is very hot. As it flows
through the condenser, the heat from the refrigerant is transferred to the air, which cools
the refrigerant down. The cool refrigerant then flows to the evaporator, where it absorbs
heat from the air inside the car, cooling the air down.
If the condenser fails, the refrigerant will not be able to cool down properly, and the air
conditioning system will not work properly.

The Second project is related to Viscous Clutch fan which is generally used in commercial
vehicles. It is a fluid coupling that automatically adjusts the speed of the fan according to
the temperature of the engine. This helps to ensure that the engine is properly cooled
without wasting fuel.

Viscous clutch fans work by using a thick fluid that is held in a sealed housing. The housing
is connected to the fan and the water pump. When the engine is cold, the fluid is thick
and the fan spins slowly. As the engine warms up, the fluid thins out and the fan spins
faster. This allows the fan to provide more airflow when the engine is hot and less airflow
when the engine is cold.

Viscous Clutch fan manufactured in MATS are of three types which are:
1. ERM Visco Clutch Fan
2. Bimetal Visco Clutch Fan
3. E-Visco Clutch Fan
They all have different working principles. ERM Visco Clutch Fan consists of an
electromagnetic coil setup which has a hall sensor, a coil, and two diodes for the circuit
operation.

These projects are affiliated with the Quality Department of Mahle Anand Thermal
Systems.

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4. PROJECT STATEMENT

The initial project aimed to reduce the scrap/rework rate for the Z101 condenser model,
which was initially over 3.5%. However, through the completion of the project, the rate
was successfully brought down to under 1%. This condenser is a crucial component of
Mahindra's new Scorpio N air conditioning system. The project followed the DMAIC
(Define, Measure, Analyse, Improve, Control) methodology of Six Sigma, a data-driven
approach that utilizes statistical techniques to identify and eliminate the underlying
causes of process defects. For the purpose of root cause analysis, the Fault Tree Analysis
method was employed.

The second project involved the development of a mobile setup for testing the ERM coil
used in the ERM Visco Clutch Fan Model. The coil casing contained an electromagnetic
coil, two diodes, and a hall sensor. Each coil was checked for its resistance, the
functionality of the diodes, and the functionality of the hall sensor. When customers filed
complaints about the functionality of the fan, the entire lot of the product that had been
sold had to be recalled and tested at the company. As the coil was a critical part, it was
always checked first and was usually the source of the problem. The goal of this project
was to create a mobile setup that would allow engineers to test the coil at the problem
site, eliminating the need to recall the product to the company's premises.

The third project entailed the revision and enhancement of the assembly line
documentation for the Bi-Metal and E-Visco models of the company's viscous clutch fan.
The objective was to align the documents with the actual processes taking place on the
shop floor, thereby optimizing the overall process efficiency. The revised documentation
encompassed Process Flow Diagrams (PFDs), Control Plans, Product Parameter Sheets,
and Process Parameter Sheets. This initiative aimed to ensure that the documentation
accurately reflected the current manufacturing practices, facilitating standardized and
streamlined operations within the assembly lines.

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 Chapter 2 – Scrap/Rework Reduction for
Condenser Model Z101

1. OBJECTIVE
The primary objective of the project is to reduce the occurrence of condensers that
require rework or are ultimately discarded following the completion of the entire
assembly process.

2. INTRODUCTION

The condenser in an automobile is a component of the air conditioning system that is

designed to remove heat from the refrigerant gas and convert it into a liquid. The
condenser is typically located in front of the engine's radiator, where it can receive a flow
of cool air to aid in the heat exchange process. MATS produce a range of models of
Condensers for different commercial and passenger vehicles.

The concept of First Time Right (FTR) aims to ensure that any task is carried out correctly
from the first attempt and consistently thereafter. This approach involves dedicating
more time initially to set up the production process accurately, which ultimately saves
resources and time that would otherwise be used to correct errors later on. This concept
originates from the Six Sigma Model. The Six Sigma model is based on a data-driven
approach that uses various statistic techniques to determine and eliminate the root
causes of defects in a process. It follows a structured methodology called DMAIC (Define,
Measure, Analyse, Improve, and Control) to drive improvement in business processes.

Figure 1 DMAIC

One of the recently developed model is Z101 Condenser which has a customer in India.
This has been one of the most challenging products for development in MATS because of
its very thin tube and fin structure. There have been a number of problems with the
quality of this product and intensive rework is required for the correction of

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manufacturing defects in this product. Also, the scrap rates are really high for this product
which may reach up to 14% at times.

2.1. COMPONENTS OF CONDENSER

Figure 2 Exploded View of Z101 Condenser

2.1.1. FINS
The extended surface used to increase the rate of convective heat transfer is known as a
fin. Fins are typically used on the surface where the heat transfer rate is insufficient to
cool or heat the body without the use of fins.

Figure 3 Fins

2.1.2. TUBES
The coolant flows from the radiator through the tubes, through the engine to absorb
excess engine heat, and back to the radiator. These are generally made up of aluminium.

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 Figure 4 Tubes

The Tubes and Fins together makeup the main part of the condenser which is the Tube
and Fin Matrix.

2.1.3. MANIFOLDS
Within the condenser, there are two manifolds that provide support to the matrix and
facilitate the seamless circulation of coolant through each tube. The Classic Manifold
governs the inflow and outflow of both the cool and hot coolant in the condenser, while
the Komo Manifold, positioned opposite to the Classic Manifold, regulates the internal
flow of coolant within the condenser. They can be seen in the exploded view of the
condenser in figure above.

2.2. INTERNAL DEFECTS

Several quality issues that are persisting in this model are:

• Tube To Header (TTH) Leakage

Leakage of coolant being observed at the points where tube is inserted into manifolds

Figure 5 TTH Leakage

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• Fin Drop
When the compression of the core is not of the specified value the fin drop occurs due
to lose attachment.

Figure 6 Fin Drop

• Bracket not brazed to cover

Brazing was not being done on this joint in Nocolok Brazing Furnace.

Figure 7 Unbrazed Bracket

• Baffle Leak
Leak of coolant from end of manifolds through the baffles.

Figure 8 Baffle Leak

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3. PRIOR WORK
The preliminary phase of this project required an extensive and comprehensive
examination of the assembly line, encompassing key components such as the core builder
machine, the Nocolok Furnace brazing process, the fin and tube assembly process, and
culminating in the final testing procedures.
The analysis conducted by the quality team revealed a critical finding: TTH (Tube-to-
Header) leakage emerged as the predominant factor contributing to the rejection of
condensers. Approximately 60% of the condensers that underwent rework or were
rejected during the End-of-Line (EOL) testing phase exhibited this specific issue.
Understanding the urgency and significance of this matter, the company swiftly identified
the need to address and rectify TTH leakage as an absolute priority.

In light of these findings, the company recognized that successful mitigation of TTH
leakage was pivotal in enhancing the overall product quality and performance. Resolving
this challenge would not only result in a reduction of rework and rejected units but also
significantly boost the overall output of the assembly line, saving time and resources
required for rework.

4. METHODOLOGY
TTH leakage, or Tube-to-Header leakage, can occur during or after the brazing process.
This problem arises when there is a coolant leakage at the junction where the tube is
inserted into the manifold (header). Several factors can contribute to this issue, including
improper brazing techniques, incorrect material selection, inadequate flux composition,
irregular furnace temperatures, and various other potential causes.

Figure 9 TTH Position

In the figure above, a light was placed beneath the insertion point. As it can be observed, in some
cases the light is leaking form one side and in a few, it is coming out from both the sides. This shows
the unbrazed insertions.

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To address all the probable causes of TTH leakage, a top-down approach for Root Cause Analysis
was followed, which is the Fault Tree Analysis (FTA).

Figure 10 FTA Chart

To tackle the various branches in the Fault Tree Analysis (FTA) chart, it was crucial to
pinpoint the exact points of leakage. To achieve this, data collection was conducted over
a period of three weeks, tracking the trend of TTH leaks' locations.

Figure 11 Points for marking TTH

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The following trend was observed:

The graph suggests that most of the problems were occurring in the middle part of the
condenser, those too specifically in tube numbers 33, 34 and 37. Also, only the Komo side
of the model were the most issues occurring. Next the Design of Experiments (DOE)
approach was used to resolve the list of probable issues.
Now, since TTH is a brazing problem, it was first checked if the brazing was done properly
in the NOCOLOK Furnace. Temperature measurements at various locations on the
condenser were done to detect any abnormal temperature differences between areas
where the issue occurred and other parts of the furnace during the brazing process. To
achieve this, a datalogger capable of measuring temperature ranges from −100°C (-148°F)
to 1,370°C (2,498°F) was utilized. Probes were set up to record the temperature data, and
the resulting graph presented the temperature readings at different points where the
probes were placed. The following graph was inferred form the probe data:

Figure 12 Temperature Inside the Furnace

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Consistent trends were noticed across different shifts of the production process. The ideal
brazing temperature, necessary for the cladding to melt and create strong bonds was
577°C, and every part of the condenser met that temperature. So, there was no problem
in the furnace process.

To inspect for any insertion-related problems, a cut section view of the manifolds was
examined.

Figure 13 Section View of Manifold

Similar observations were made when examining the samples under a microscope.

Figure 14 Insertion under Microscope

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Upon examining the cut section view of the manifolds, two crucial findings came to light:

• Tube Integrity: It was evident that the tubes inserted in the assembly were intact
and undamaged. This observation ruled out any physical damage to the tubes
during the insertion process. Instead, it pointed towards the possibility of an issue
with either the header slot being oversize or the tube dimensions being
undersized.
• Brazing Pattern: The analysis of the missed brazing revealed a consistent pattern.
The absence of brazing was uniformly noticed along the width of the tube and not
along its length. This observation indicated that the tube's lengthwise positioning
was not a contributing factor to the problem, eliminating the need for any
modifications in this aspect. Rather, the width of it needed to be altered.

Firstly, it was assumed that it was a tube undersize issue and a different supplier for the
tube was taken up. The comparison between the size of new tube (Honda) and the old
tube is shown in the table below:

Table 1 Size Comparison

It was observed that replacing the tubes with new Honda tubes did not result in any
significant changes in the rejection rate. Surprisingly, the rejection rate remained almost
the same, despite the tube replacement. As a result, the focus shifted to exploring other
potential causes.

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 With the tube dimensions eliminated as the primary factor, the attention turned towards
investigating the slot width in the header. It was hypothesized that variations in the slot
width might be contributing to the brazing issues observed earlier.

So, the supplier responsible for providing the manifolds was directed to closely examine
the slot widths. As a corrective measure, it was decided to decrease the slot widths by
20 microns uniformly across all the slots. To ensure consistency and precision, this
change was implemented in every slot by making adjustments to the punching die.

The decision to reduce the slot width proved to be a pivotal step in addressing the issue
of missed brazing and high rejection rates. With the narrower slot dimensions, the tubes
were now positioned more securely in the header, facilitating better alignment and
ensuring improved brazing during the assembly process.

Upon implementing the adjusted slot width, the impact was clearly visible in the
production line. The rate of rejection witnessed a significant decrease, leading to fewer
condensers needing rework and a marked improvement in the overall product quality.

5. RESULTS
The scrap rate for the Z101 model before and after implementing the changes stated in
the methodology above showed the following change:

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 As per the data collected for two weeks after implementation of the changes to resolve
the TTH issue, following was being observed for the remaining rejection:

6. FUTURE SCOPE OF WORK

In the future, the company may consider addressing additional issues such as baffle leak
and unbrazed brackets to further reduce the rejection rates. However, it is essential to
note that the potential benefits gained from rectifying these issues might be relatively
limited compared to the efforts and resources required for their implementation.

While addressing these additional concerns could contribute to incremental

improvements in product quality and rejection rates, it is crucial for the company to
conduct a comprehensive cost-benefit analysis. Evaluating the return on investment and
assessing the impact on overall production efficiency will aid in making informed
decisions.

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 Chapter 3 – Design & Implementation of an ERM
Coil Testing Device

1. OBJECTIVE
The purpose of this project is to design and develop a portable ERM coil testing device.
This device would eliminate the need to recall coils that require retesting, as an engineer
could perform an on-site inspection instead.
2. INTRODUCTION
A viscous clutch fan is a cooling system component used in many vehicles, especially in
older models and heavy-duty applications. It plays a crucial role in regulating the engine
temperature by controlling the airflow through the radiator. The module controls the fan
speed by altering the amount of a viscous liquid in the working chamber and reservoir.
The transfer of oil (viscous liquid) is controlled by a valve lever. Now, the valve lever
operation can be controlled by various methods and based on that, different varieties of
Visco Clutch exist.

At MATS, the production of viscous clutch fans encompasses three main types:

• Bimetal Clutch - In this type, the valve lever operation is controlled by a spring
connected to a bimetal strip. The bimetal strip undergoes shape changes in
response to fluctuations in engine temperature, enabling the regulation of the fan
speed accordingly.
• E-Visco Clutch - Unlike the Bimetal Clutch, the E-Visco Clutch replaces the bimetal
strip setup with an electronic module. This module senses the engine temperature
and activates an electromagnetic coil responsible for controlling the valve lever
operation, leading to precise fan speed adjustment.
• Electronically Rear Actuated Magnetic (ERM) Visco Clutch -The ERM Visco Clutch
functions similarly to the E-Visco Clutch. However, the key distinction lies in the
placement of the coil. In the ERM Visco Clutch, the coil is positioned away from
the engine to ensure that the components are shielded from potential damage
caused by engine heat.

This project is associated with the ERM Visco Clutch, focusing on the coil housing used in
the ERM Visco Clutch fan. The coil housing contains essential components, including a hall
sensor, an electromagnetic coil, and two diodes, which are crucial for the circuit's
operation. The complete housing is sourced externally from a supplier.

To ensure the proper functioning of the coil when integrated into the Fan module, a
dedicated station is available. This station allows for the assessment of various
characteristics of the coil like coil resistance, input current, diode status and verifies the

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 functionality of the hall sensor. This testing process ensures the reliability and
performance of the ERM Visco Clutch system.

Figure 15 ERM Coil

The coil was further of 2 types, a 24V input and a 12V input coil. These were being used
in ERM45, ERM120, and ERM65 models of Visco Fan.

Table 2 Coil Test Parameters

ERM 45 ERM 120 ERM 65
Station Parameter Description Class
Min Max Min Max Min Max

Coil Resistance (Ohm) 30 35 30 35 30 35

Coil Current (A) 0.4 2 0.4 2 0.4 2

Coil Check
Coil Hall Sensor Count 6 6 6

Coil Voltage (V) 18 28 18 28 18 28

A requirement arose for the design of a portable device capable of performing essential
functions similar to those of the existing testing station. This need arose due to certain
situations where products necessitate recall to the MATS premises for coil testing. To
address these circumstances efficiently, the proposed portable device would enable an
engineer to conduct on-site coil inspections.

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 2.1. COIL PARTS

The internal structure of the ERM Coil is as below:

Figure 16 Coil Internal Circuit

The A, B, C, D and E points are the connected to the vehicle for operation.

The coil employs a hall sensor in the form of an IC known as ATS668, which incorporates
Rout, Rsupply, Cout, and Csupply components within it.

In addition, the coil includes two diodes, specifically STTH1002c, which serve crucial
protective functions for the circuit. One of the diodes (D2) acts as a freewheeling diode,
ensuring safe dissipation of back EMF when the coil is switched off. The other diode (D1)
serves as a preventive measure, safeguarding the outer circuit from potential damage
caused by reverse current flow.

3. METHODOLOGY
The parameters that we need to measure using the instrument are:

• Hall Sensor Reading –

To assess the functionality of the Hall sensor while rotating the coil, a
straightforward approach involves feeding the sensor's input to the
microcontroller. The established standard for this assessment is based on 6
rotations, using a conveniently available gauge in MATS.

• Resistance of Coil –
To accurately determine the resistance of the coil, a Voltage Divider Circuit is
employed. This circuit consists of a shunt resistor connected in series with the coil,

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 dividing the voltage across the coil into measurable values. The voltage sensor or
amplifier, integrated into the circuit, facilitates the precise measurement of these
smaller voltage values. All the necessary data and measurements are processed
by the microcontroller, which plays a central role in this setup. The microcontroller
performs the required calculations based on the voltage readings from the sensor
or amplifier, converting the measured voltage drop into the corresponding
resistance value. The result is then conveniently displayed on an LCD screen.

Figure 18 Coil Circuit Figure 17 Voltage Divider Circuit

• Condition of Diodes D1, D2 (Working/Not Working) –

To simplify the design and implementation of our circuit and to reduce the number
of voltage supplies required, we have established specific conditions for testing
Diodes D1 and D2.

For Diode D1, we focus on its functionality in forward bias. This is crucial because
if the diode fails to operate in forward bias (rendering our circuit open), the entire
circuit will not function properly. It is essential to ensure that the diode allows
current to flow in the intended direction, as this directly impacts the overall
operation of the circuit. On the other hand, checking D1 in reverse bias is not a
primary concern, as any malfunction in this scenario would not directly affect our
coil but may pose a slight risk to the vehicle's circuitry.

Regarding Diode D2, our attention is directed towards its performance in reverse
bias. The reason behind this emphasis is that if the diode fails to operate in reverse
bias (causing the circuit to close), there will be no current passing through the coil,
rendering it non-functional. On the other hand, if D2 does not work in forward
bias, where a flyback effect occurs, there might be some residual current in the
coil. However, this residual current is of less concern, as it will dissipate over time
and is unlikely to cause significant issues.

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3.1. CIRCUIT DESIGNS PROPOSED AND FINALIZED
During the design phase, several possible circuit configurations and approaches were
thoroughly discussed, each offering its unique set of benefits and considerations. Here,
we elaborate on some of these potential designs

3.1.1. DESIGN 1
The proposed design allows the instrument to be powered either by an external AC
source or by the vehicle's battery pack. This dual power capability ensures that the
site engineer can still take readings even in situations where the AC source is
unavailable during the measurement process.

Figure 19 Proposed Layout 1

However, utilizing the vehicle's battery pack as a power source for the instrument
proved to be impractical. The product is commonly installed in commercial vehicles,
with its location typically being in front of the radiator, near the front of the vehicle.
On the other hand, the battery is usually positioned near the center of the vehicle,
quite far from the instrument's location. As a result, extensive wiring would be
necessary to connect the two, making this design unfeasible. Consequently, this
approach was abandoned in favor of more practical power supply options.

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3.1.2. DESIGN 2
In this design proposal, a standardized power supply of 12V was adopted for both 12V
and 24V coils. The rationale behind this decision was that the voltage sensor values
would automatically adjust to the specific characteristics of different coils. To ensure
accurate measurements, the user would be able to select the coil type directly on the
microcontroller. By making this selection, the microcontroller would then perform the
necessary calculations and adjustments, allowing precise conclusions to be drawn
based on the chosen coil type. This approach simplified the power supply
requirements while maintaining flexibility and accuracy in the instrument's
measurements. Also, this would reduce cost of the instrument.

Figure 20 Proposed Layout 2

The proposed design was not feasible due to several limitations. Using a standardized
12V power supply for both 12V and 24V coils caused significant issues. Firstly, the 24V
coil would be unable to function properly with a 12V input voltage, rendering it
inoperable. Secondly, forcing a 24V coil to operate under a lower voltage would lead
to excessive load on the power supply, potentially causing damage or instability. These
constraints made it clear that a single, fixed voltage supply for both coil types would
not be suitable, necessitating a different approach for powering and operating the
coils effectively.

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3.1.3. DESIGN 3
This design was nearly identical to the final design, with the only variations being the
specifications of the DC-DC converter and the power inputs for the Hall sensor
including the use of pull up resistor. All other aspects of the design remained
consistent, showcasing the effectiveness of the concept.

Figure 21 Proposed Layout 3

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3.2. FINAL CIRCUIT AND COMPONENTS
The final detailed circuit, the result of discussions and considerations incorporating the
concepts mentioned above, took the following form:

Figure 22 Final Layout Detailed

Circuit Componentry and Functioning:

• Power Input (AC) – EMI_21_X
This power input is used to take the AC Supply input to the instrument. This has
an inbuilt fuse in it so there is no need to use an external one.
• Switch (ON/OFF Operation)
Here, we use a simple switch which starts the current supply to the circuit. This
serves the purpose of safeguarding the instrument at times its not in use but the
AC Supply is connected to it.
• Power Supply AC-DC Converter 24V - PMT24V50W1AA
The 24V power supply is used here which converts the AC input to usable 24V DC
signal which will be used to power and test the 24V ERM Coil. The input from it
further goes into the DPDT switch. The power rating for this power supply is 50W
which will be required in our circuit.
• Power Supply AC-DC Converter 12V – PMT12V50W1AA
The 12V power supply is used here which converts the AC input to usable 12V DC
signal which will be used to power and test the 12V ERM Coil. The input from it
further goes into the DPDT switch, the DC-DC converter, and the relay switch we
use in circuit further. The power rating for this power supply is 50W which will be
required in our circuit as the power supply is power various components.
• Step Down DC-DC Converter - LM2596S 12V-9V
The 9V signal is required in the circuit to power the Arduino Board that we are
using in the circuit as our main microcontroller. In the circuit, the input for this

31
 buck comes form the 12V power supply and output goes into the microcontroller’s
pins.
• DPDT Switch (Source Selection)
A DPDT (Double Pole Double Throw) switch is an electrical switch that has two
independent circuits, each with two possible connection states. It consists of six
terminals: two common terminals (COM) and four other terminals (NO1 and NC1
for the first circuit, and NO2 and NC2 for the second circuit). In its default state,
the common terminals are connected to the normally closed terminals for both
circuits. When the switch is actuated or toggled, it moves to connect the common
terminals to the normally open terminals, breaking the connection with the
normally closed terminals in both circuits.
In the circuit, the outputs of the DPDT switch are shorted and both given as input
to the relay of the circuit. The job of this switch is to allow the user to select the
power supply to coil (12C/24V). The normally open terminal is grounded, again, to
safeguard the instrument.
• Relay 1 Channel 12V
A relay is an electromechanical device that acts as an electrically operated switch.
The "1 channel" designation indicates that this particular relay has a single set of
contacts. In other words, it can control a single circuit or load at a time. Some
relays have multiple channels, allowing them to control multiple circuits
independently. The "12V" indicates the voltage required to energize the relay's
coil. This means that the relay requires a 12-volt direct current (DC) input to
activate the electromagnet and switch the contacts. It's important to ensure that
the relay receives the correct voltage to function correctly and reliably.
The purpose of relay in this circuit is to start the testing procedure on the push of
a button. This is to ensure that the coil does not remain constantly power by the
supplies and supplied to it can be halted using the push button that controls the
relay.
• Push Button (Latching)
A basic push button is employed in the circuit, and when pressed, it establishes a
connection between the shunt and ground. This connection completes the
circuit, allowing the current to flow through the coil. In this way, the push button
acts as a simple switch to control the current flow through the coil by effectively
engaging or disengaging the shunt.
• Shunt – 5A/100mV Shunt
A shunt refers to a low-resistance path or component deliberately connected in
parallel with a load or circuit element. The primary purpose of a shunt is to
measure the current flowing through the load or circuit by detecting the voltage
drop across it. The notation "5A/100mV shunt" describes a specific type of shunt
resistor. the shunt is designed to handle a maximum current of 5 amperes and
when 5 amperes of current pass through it, there will be a voltage drop of 100
millivolts (0.1 volts) across the shunt.

32
 One can observe that the voltage drop for a 5 Ampere current through the shunt
is very low. Consequently, the presence of this shunt in the circuit will have
minimal interference on its overall functioning and will not significantly alter the
voltage drop across the coil or impact its performance. The shunt's low
resistance ensures that it effectively measures the current without introducing
any substantial disturbances to the circuit's operation.
• Voltage Sensor – AD620 Amplifier
Due to the extremely low voltage drop across the shunt (100mV) even at the
highest current levels, a standard voltage sensor module is unsuitable for this
application. To address this issue, an amplifier can be employed. The amplifier's
function is to boost the weak analog signal from the shunt to a higher level,
making it more easily measurable with improved accuracy. By amplifying the
signal, the measurement becomes more reliable, allowing for precise current
measurements across the resistance.
The amplifier module is powered by DC-DC Converter and the output from it
goes directly to the analog pins of the Arduino Mega R3 to interpret them.
• Microcontroller - Arduino Mega 2560 Rev3
The Arduino Mega 2560 Rev3 stands out as an advanced microcontroller board
centered around the ATmega2560 microcontroller. Its selection is primarily
driven by its high clock speed of 16MHz, which boosts its processing capabilities.
Additionally, its seamless compatibility with the Arduino IDE simplifies coding,
command execution, and calculations. For further details and comprehensive
documentation about the board, one can refer to Arduino's Official Website,
which provides comprehensive information on all Arduino boards, including the
Arduino Mega 2560 Rev3.
• Pull Up Resistor 200 Ohm
Arduino Mega microcontroller work with digital logic levels (HIGH and LOW). By
using a pull-up resistor, the output of the Hall sensor can be converted into a
digital signal. When the Hall sensor detects a magnetic field, it actively drives the
output low, overcoming the pull-up resistor and creating a clear digital LOW
signal. When there is no magnetic field, the pull-up resistor pulls the output to a
HIGH state, representing a digital HIGH signal.
A few calculations suggested the value of the resistor should be 200 Ohm.
• Display - JHD LCD 20X4 (with i2c)
The JHD LCD 20x4 with I2C is a versatile alphanumeric display module that
features a 20-character by 4-line LCD screen. Its I2C interface simplifies
communication with other devices, utilizing just two wires for efficient data
transfer. With a backlit display, the module ensures readability even in dimly lit
environments. The option to adjust the contrast further enhances visibility. Its
compatibility with 5V logic levels makes it suitable for various microcontrollers
and Arduino boards.
In our circuit, we employ the JHD LCD 20x4 with I2C to display essential
information to the on-site engineer.

33
3.3. CALCULATIONS

The shunt resistor employed in the circuit exhibits extremely low resistance. As a
result, its impact on the overall current flowing through the circuit is negligible.
Essentially, the shunt introduces minimal interference, thereby ensuring the circuit's
current flow remains largely unaltered. Consequently, when calculating the current,
it is sufficient to primarily focus on the main resistance stemming from the coil.

To calculate the current through the coil, Ohm’s Law is used.

For Coil Resistance:

Shunt Specifications:
The shunt gives a voltage drop of 100mV for a current of 5A.

Current Measurement Requirement:

The maximum current that we need to measure is 2A. Hence, the voltage drop
across the shunt would be:

Vshunt = (40mV/2A) * Current_to_measure = 40mV/2A * 2A = 40mV

AD620 Amplification:
To amplify this 40mV to the maximum output voltage of AD620 that will go into
Arduino, which is 2V, we need an amplification gain (G) of 50.

G = Vout / Vin = 2V / 40mV = 50X

34
Coil Resistance Calculation:
Now, if the current in the circuit is 'x' Amperes, the voltage drop on the shunt resistor
will be 20x mV (derived from 100mV/5A * xA), and the output of AD620 amplifier will
be x Volts (from 20x mV * 50).

For both coils, a 0.7V drop would occur due to presence of Diode D1

For a 24V Coil:

The coil resistance (R24V) can be calculated using Ohm's law as:

R24V = V/I = (24-0.7)V/x A

For a 12V Coil:

The coil resistance (R12V) can be calculated as:

R12V = V/I = (12-0.7)V/x A

For Diode D1:

It's crucial to determine if Diode D1 is operating correctly only in a forward bias
condition, due to the reasons previously discussed. An uncomplicated method to
verify this is by inspecting the voltage output from the AD620 amplifier.

If there's no voltage detected across the shunt, it implies that the circuit isn't
conducting any current, suggesting a possible circuit breakage. This situation arises
when Diode D1 isn't functioning in a forward bias mode, resulting in a circuit
configuration as depicted below, rendering the circuit ineffective.

Figure 23 D1 not OK

Overall, if voltage drop across shunt = 0 V

Diode D1 is not OK.

Under such circumstances, it's impossible to assess the resistance of the coil or
determine the operational status of Diode D2.

35
For Diode D2:
It's crucial to determine if Diode D2 is operating correctly only in a reverse bias
because of before mentioned reason. When the D2 in working in reverse bias, circuit
would look like this:

Figure 24 D2 not OK

This circuit provide an alternate path for the current to flow, rendering the coil
useless and shorting the circuit. Here, the shunt output would be maximum, which
AD620 would not be able to process it and there will be no output.
Again, in this case we cannot measure Coil Resistance.

If there is no output
Diode D2 is not OK

For Hall Sensor:

The hall sensor output was very low for Arduino to interpret so a pull up resistor had
to be used. The pull-up resistor ensures that the Arduino pin reads a known state
(HIGH) when the sensor is not activated.

The exact value for pull-up resistor isn't critical in most cases, but one shouldn't use
extremely low values (like 1Ω) because when the sensor is activated, it would create
a short circuit to ground, which draws a high current from the power supply. Too high
a resistance (like 1MΩ) might not pull the voltage high enough, or make the circuit
sensitive to interference. So, 200 Ω is selected.

The input is given into a digital pin of Arduino and a counter is used to calculate the
number of rotations of the coil.

36
 Arduino 2560 Mega Rev3:
The Arduino Mega has a 10-bit analog-to-digital converter. This means it can
represent an analog value by a digital number between 0 (representing 0V) and 1023
(representing the reference voltage which is typically 5V).

So, each step represents:

5V/1024 values = 0.00488V or 4.88mV per step = 0.0049V

To read 2V from an analog pin in Arduino Mega, one would read a value of about 410
by the formula:
2V/0.00488V per step = 409.83

Voltage (in Arduino) = Analog_Reading * (5.0/1023)

Now this value can be used to draw conclusions about the coil using above formulae.

The above equations were implemented in the Arduino IDE's code, and the results
were displayed on the I2C display board utilized in the setup.

4. RESULTS
The estimated cost for this instrument was about 11000 INR. The cost-breakup is shown
below:
Table 3 Components Cost Sheet

Components List
Components Model Datasheet Cost
Controller Arduino Mega 2560 Rev3 A000047 (Arduino Mega 2560).pdf ₹ 3,099.00
Display JHD LCD 20X4 (with i2c) LCD 20X4 jhd.pdf ₹ 599.00
Power Supply AC-DC 24V PMT24V50W1AA Datasheet_PMT-24V50W1AA (AC-DC).pdf ₹ 3,500.00
Power Supply AC-DC 12V PMT12V50W1AA Datasheet_PMT-12V50W1AA (AC-DC).pdf ₹ 3,300.00
Step Down DC-DC LM2596S 12V-9V lm2596 (Step Down DC-DC).pdf ₹ 60.00
Relay 1 Channel 12V ₹ 60.00
Shunt 5A/100mV Shunt ___
Voltage Sensor AD620 Amplifier ad620 voltage amplifier.pdf ₹ 422.00
Switch Normal <20
Switch DPDT <20
Push Button Locking with Light (Test/Reset) <20
Keypad 4X1 keypad Arduino ₹ 120.00
Power Input EMI_21_X EMI-21-X (power input).pdf <100
Pull Up 200 Ohms Resistor <20
Electronic Enclosure Box Generic ___

This project has a profound impact on MATS' operations, primarily by significantly

reducing the transportation costs associated with bringing the coils back for testing—

37
 this is a tangible financial benefit. It eliminates the need for back-and-forth
transportation of the coils, resulting in substantial cost savings.

Moreover, beyond the immediate financial gains, the project also enhances customer
satisfaction. By enabling on-site coil testing, it drastically reduces the time previously
required for transportation and testing, leading to faster resolution times. This improved
efficiency is likely to boost customer confidence in MATS' services.

In essence, the project delivers not only clear economic advantages but also contributes
to a better customer experience. By facilitating quick and efficient on-site testing, it
ensures that MATS' services remain responsive and customer-centric, further solidifying
its reputation in the market.

5. FUTURE SCOPE
The instrument that would be capable to perform:
• Measurement of resistance and the condition of Diode 2 (D2) when Diode 1 (D1)
is non-functional.
• Measurement of coil resistance when Diode 2 (D2) is non-functional.
• Assessment of Diode 1 (D1) under reverse bias conditions.
• Assessment of Diode 2 (D2) under forward bias conditions.

38
 Chapter 4 – Process Improvement for Viscous
Clutch Fan Models

1. OBJECTIVE
To revise the business's documentation pertaining to the Viscous Clutch Fan series. The
materials to be updated comprise Process Flow Diagrams (PFDs), Control Plans, as well as
Product and Process Parameter Sheets.
2. INTRODUCTION
India as well as in Germany. The purpose of Viscous Clutch Fan (Visco Fan) is to improve
the engine efficiency of commercial vehicles by cooling the engines at higher RPMs and
stay inactive, i.e., do not draw power from engine at lower RPMs where much cooling is
not required. It has three types that are manufactured in MATS, Bimetal, E-Visco and ERM
Model.
This project aimed to update the documentation related to the Bimetal and the E-Visco’s
assembly lines.
The PFD is a visual chart that helps to identify the inputs, outputs, and critical control
points in the manufacturing process. It helps to understand the sequence of operations,
the equipment and resources required, and the interactions between different stages of
the process. PFD is typically created by a cross-functional team that include employees
from various departments such as production, engineering, quality control, and logistics.
A Control Plan provides a single point of reference for understanding process
characteristics, specifications, and standard operating procedures -also known as SOP- for
the process. A CP allows for the assignment of responsibility and allocation of
accountability for each activity within the process. This ensures that the process is
executed smoothly and is sustainable in the long run.
Process and Product parameter sheets include all the constraints related to the process
that are followed on the line and also the CTQ (Critical to Quality) measures that the final
product must align to. These parameters are the variables that must be carefully
controlled to ensure that the product meets its design specifications and quality
standards.

3. PRIOR WORK
The preliminary phase of this project involved a detailed comprehension of the assembly
line procedures. This involved studying all the existing documents pertaining to quality
control on the assembly line. This study encompassed FP/LP reports (First Piece/Last Piece
Report), Material Selection Matrices, Tool Selection Matrices, Work Instruction
Checksheets, Run Charts, Process Flow Charts, among others. The Heijunka Plan was used

39
 as a valuable resource to understand all the subsidiary components employed at each
station.
Moreover, it was crucial to carefully monitor the operations at every station, including the
CTQ measures for each, along with the subsidiary parts employed there. The aim was to
meticulously document every detail.
To guarantee the revised documents fulfilled the requisite standards, an exhaustive
analysis of similar, up-to-date documents related to other products was performed. The
purpose of this review was to establish a benchmark for the updated documents'
expected quality standards.
This method is an integral part of the Improve stage of the DMAIC framework in the Six
Sigma Model.

4. METHODOLOGY
4.1. PROCESS FLOW DIAGRAM
For the Process Flow Diagram, the initial step was to comprehend the sequence of
stations or steps through which the product moved, and record this information. For
the Bimetal Visco Fan, following sequence was observed:

Figure 25 Proces Flow Bi-Metal

40
 Similarly, the process flow for E-Visco Fan line was observed to be as follows:

Figure 26 Process Flow E-Visco

Then, unique operation numbers were given to each station and a flow chart with all
those numbers was made.
Next step was to identify the incoming sources of error at each operation for which,
consultation with the quality team and also discussion of the issues with the Operating
Engineers at the line was required. The product and the process characteristics for
each operation were decided only after discussing with the quality team as well. A
final revision was given to PFD and then, it was made available on the assembly line.

4.2. CONTROL PLAN

For the next task, the control plan of the all the processes was to be updated. Some
of the stations were newly added in the PFD, so, a complete sheet for their Control
Plan had to be made.
A Control Plan requires the following details about a station:

• Product and Process Characteristics

• Product/Parameter Specification
• Evaluation Measurement Techniques
• Sample Size and Frequency of measurements
• Control Method (Prevention and Detection)
• Responsibility, Reaction Plan, and Corrective Actions

41
 The specifics needed to be addressed in consultation with the Cell Coordinators,
Operating Engineers, and Quality Control team. A sample CP for the bearing pressing
station is given below:
Table 4 Control Plan Sample
Characteristics Evaluation
Special Product/Process Sample Size Frequenency Control Method Corrective Action Plan/
Measurement Responsibility Reaction Plan
No Product Process Char. Specifications Responsibility
Technique By Operating Engineer Prevention Detection

Fixture Selection Fixture Selection as per model Visual 1 Each Setiup Set up Checksheet OE Follow WI

Machine will not start if sensor does

not sense fixture position
correct positioning of fixture with Check the fixture position and set
Fixture position Presence sensor 1 Nos. setup 'Set up checksheet OE
dowel with dowel
Setup checksheet No.
(Doc no. EV/SCC/BP1-V04)
1

Program Name- As specified in
Program
'Set up Work Instruction
Selection
(EV/WI/Setup/BP1-V04)
Set up checksheet
Visual Display on Each model/setup Set up Work Instruction (Doc no.EV/SCC/BP1-V05) If Program no. not available Escalate to Maintenance and
1 OE
the Screen change (EV/WI/Setup/BP1-V04) / First piece/Last piece contact to cell co-ordinator Resolve the issue/CC
(Doc no. EV/FPA/BP1-V05)

1.adjust the pressure knob to get

Visual inspection Start and end of shift report desired pressure
Air pressure 5 ± 1 bar 1 Nos. Shift OE
of pressure guage (Doc No. F/EV/PRD/BP1-V05) 2.If pressure is not getting Inform
to cell cordinator

Minimun &
If oil level is below minimum
Oil presence in oil Availability of oil in tank as per maximum level Work Instruction Start and end of shift report
1 Shift OE level mark Inform to cell co- Fill lubrication oil/CC
tank defined level identification on (EV/WI/PRD/BP1-V05) (Doc No. F/EV/PRD/BP1-V05)
ordinator
oil tank

Bearing Selection
As per Child Part Selection Visual Inspection - Setup
2 (Child Part Visual Inspection 1 100% OE
Matrix Checksheet
Selecetion)

Bottom Housing
Sleection As per Child Part Selection Visual Inspection - Setup
Visual Inspection 1 100% OE
(Child Part Matrix Checksheet
Slecetion)

100% Visual Inspection, & First

Bearing
Blue Seal on Upper Side Visual Display 100% Continous piece & last Piece approval(Doc no. OE Reject
Orientation
: EV/FPA/BP1-V05)

Pokayoke - Sensor to S'tart and end of shift report If the Photo sensor pokayoke not Escalate to Maintenance and
Bearing presence 01Nos Sensor 100% Continous OE
check the presence of bearing (Doc No. F/EV/PRD/BP1-V05) working inform to CC Resolve the issue/CC
3

Bottom housing Photo Sensor Pokayoke to check the presence of If the Photo sensor pokayoke not Escalate to Maintenance and
01 Nos 100% Continous Start and end of shift report OE
presence (M18) housing working inform to CC Resolve the issue /CC
(Doc No. F/EV/PRD/BP1-V05)

1.Observe if oil spray is spraying

oil or not
100% Visual Inspection, & First
Lubrication of Uniform application of oil on Work Instruction 2.If Oil spray is not spraying oil Escalate to Maintenance and
Visual Inspection, 100% Continous piece/Last piece OE
Housing I.D housing I.D. (EV/WI/PRD/BP1-V05) check the oil level in tank if Resolve the issue/CC
(Doc no. EV/FPA/BP1-V05)
observed below minimum level
contact to CC

Compare pressing
M/c control, red indication & 'First
load with the set
Pressing Load As per Process Parameter Sheet 2 Shift Piece / Last Piece Approval OE Reject Set final position /CC
pressing load in
(Doc no. EV/FPA/BP1-V05)
4 HMI

Compare actual
feed with the set first piece / last piece approval(Doc
Pressing feed As per Process Parameter Sheet 2 Shift OE Inform to cell co-ordinator Set final position /CC
pressing feed in no. : EV/FPA/BP1-V05)
HMI

Compare actual
Pressing Stroke first piece / last piece approval(Doc
As per Process Parameter Sheet position with the 2 Shift OE Inform to cell co-ordinator Set final position /CC
Length no. : EV/FPA/BP1-V05)
set position in HMI

Gap between
First Piece/Last Piece Approval
housing & Maximum gap allowed 0.05mm Feeler Gauge 2 Shift OE Reject Set final position /CC
(Doc no. : EV/FPA/BP1-V05)
Bearing,

1.Reject
5 2.Any mishandled part details
like part no.,quantity to be noted
Work Instruction in rejection checksheet
No damage first piece / last piece approval(Doc
As per Visual catalogue Visual 100% Continous (EV/WI/PRD/BP1-V05) OE Rejection Sheet No.
assembly no. : EV/FPA/BP1-V05)
'Visual catalogue 02900301 -V6
3.Check if the damage caused
due allignment of ram axis if
found misalligned inform to CC

42
 4.3. PROCESS AND PRODUCT PARAMETER SHEETS
Two distinct documents detailing Product Parameters and Process Parameters ought
to be accessible on the line. The Control Plan includes references to these sheets
which should be consulted when information about the Critical to Quality measures
for the product and Control Measures for the process is required.

With regard to the Product Parameters, I personally undertook First Piece/Last Piece
observations for all the products. Following this, tolerances were established for
each product and the data was logged into the product parameter sheet. As for the
Process Parameters, the Human Machine Interfaces present at each station proved
invaluable for recording the necessary data.

Table 5 Product Parameter Sample

T12 T35 T80
Station Parameter Description Reference drg (Example) Class
Min Max Min Max Min Max

Bearing Rolling Bearing Rolling Diameter 38.6 40 49.7 50.3 59.4 60

Primary Disc Torquing Primary Profile Runout 9.7 10.1 5.3 5.7
(Only for T35 and T80)

Table 6 Process Parameter Sample

Station Parameter Description T12 T12F T80 T80 in ERM CV-T10
Engagment Load Feed (mm) 1.20 1.20 1.00 2.50 1.00
Engagment Feed Set (mm/Sec) 5.00 5.00 10.00 4.00 10.00
Engagment Position Set (mm) 235.00 235.00 220.00 223.00 235.00
Pressing Load Set 1.50 1.50 2.50 3.00 2.50
Bearing Pressing Pressing Feed Set (mm/Sec) 2.00 2.00 3.00 2.00 3.00
Pressing Position Set (mm) 249.50 249.10 255.00 249.90 249.20
Rapied Load Set 0.50 0.50 0.50 0.50 0.50
Rapied Feed Set (mm/Sec) 50.00 50.00 50.00 50.00 50.00
Rapied Position Set (mm) 225.00 225.00 210.00 220.00 230.00
Engagment Load Feed (mm) 1.00 1.00 2.00 0.50 1.00
Engagment Feed Set (mm/Sec) 5.00 3.00 5.00 5.00 5.00
Engagment Position Set (mm) 225.18 222.50 216.50 210.05 218.00
Pressing Load Set 1.00 1.00 1.00 1.00 1.00
Bearing rolling Pressing Feed Set (mm/Sec) 0.12 0.12 0.14 0.14 0.12
Pressing Position Set (mm) 227.03 227.15 221.34 213.74 220.70
Rapied Load Set 1.00 1.00 1.00 0.50 1.00
Rapied Feed Set (mm/Sec) 50.00 45.00 50.00 50.00 50.00
Rapied Position Set (mm) 215.05 215.10 210.00 207.10 215.00

43
5. RESULTS
The revision of the Control Plan, Process Flow Diagrams (PFDs), and Product and
Parameter sheets served as a significant boon to the company in several ways. FIt
promotes an improved understanding of the assembly line processes. The updated
documents encapsulate the most recent changes, innovations, and improvements in the
process, ensuring that the entire team is working with the most accurate and up-to-date
information.

It enhances operational efficiency. The updated Control Plan and PFDs help to
streamline workflows, minimize errors, and identify opportunities for process
improvements. The updated Product and Parameter sheets provide a comprehensive
overview of product specifics and process parameters. This detailed information aids in
quality control, allowing for faster identification and resolution of issues that could
impact product quality or cause production delays.

These revisions align with the company's commitment to continuous improvement and
adherence to quality standards, such as the Six Sigma DMAIC approach. The updated
documents not only reflect the current state of operations but also lay the groundwork
for future improvements and innovations. This proactive approach to document
management can enhance the company's reputation for quality and operational
excellence.

44
 References

www.mahle.com/en/products-and-services
https://www.hortonww.com/news-and-events/news/five-reasons-viscous-fan-clutch-
application.html
https://www.chlaka.com/nocolok-flux-brazing/

https://www.researchgate.net/publication/299969001_Condensers/

https://sixsigmastudyguide.com/iassc-lean-six-sigma-study-guide/
https://www.mouser.in/new/analog-devices/adi-ad620-
amplifiers/?gclid=Cj0KCQjw5f2lBhCkARIsAHeTvljzOTNaUNi15b7PrTKrhGRN7p3xMb8meGcIoylZaPr5n
WyRJNfaqKoaAs2ZEALw_wcB

https://store.arduino.cc/products/arduino-mega-2560-rev3

https://www.deltapsu.com/en/products/panel-mount-power-supply/PMT-24V350W1AG

https://www.deltapsu.com/en/products/panel-mount-power-supply/PMT-12V150W1AA

https://www.ti.com/lit/ds/symlink/lm2596.pdf

45