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WHEELS INDIA LIMITED

SUN RISE
QUALITY CIRCLE
TR UNIT

TEAM MEMBERS

Nagendran. R
Facilitator

Member

Poosadurai.T
Leader

Member

Kannan.V
Member

Member

ABOUT OUR SUN RAISE QC

Theme:
TO ELIMINATE CUSTOMER
COMPLAINT DUE TO LOW TORQUE
PROJECT START DATE

:05.05.2013

PROJECT END DATE

:25.08.2013

PROJECT MEETINGS

:Monday

NO OF MEETINGS HELD

:12

ATTENDANCE

:85 %

Step-1 Identification Of Problem


Sl. No.

Problem Descriptrion

Wrong Assembly position

Bolt twist

Bolt nut Lossened Condition

Wrong rim/ Disc assembly

Low Torque

Double wahser Assembly

Blow Hole / Porosity

Bolt Hole damage

Excess Run Out

10

Lug inset problem

Type A Minimum involvement of other Department in Solving Them /Can be solved by the QCC Member itself
Type B - Involvement of other Department is a necessity
Type C Problems can be solved with Management assistance

Step-2 Selection Of Problem


S .No

Line

Machine /
Operation

Assembly

Manual

Assembly

Ranking Related to

Identified problem / issues

Total marks

Wrong Assembly (Position)

Manual

Bolt twist

Assembly

Manual

Bolt nut Lossened


Condition

Assembly

Manual

Wrong rim/ Disc assembly

Assembly

Manual

Low torqe

108

Assembly

Manual

Double wahser Assembly

24

Lug Weld

Primo

Blow Hole / Porosity

12

Others

Others

Bolt Hole damage

Assembly

Manual

Excess Run Out

12

10

Painting

Manual

Lug Inset variation

Ranking
1 - Low

Problem category:Assembly related


Total Marks Formula = Multiplication (P*Q*C*D*S*M)

2 - Moderate

3 - High

Problem Definition:

EP-3 DEFINE THE PROBLEM


AS IS PROCESS F
RIM
RIM
MFG
MFG

DISC
DISC
MFG
MFG

INTERNAL
INTERNAL
STORAGE
STORAGE

INTERNAL
INTERNAL
STORAGE
STORAGE

LUG
LUG
WELDING
WELDING

CED
CED
PAINTING
PAINTING

LUG
LUG
WELDED
WELDED
RIM
RIM AND
AND
DISC
DISC
ASSEMBLY
ASSEMBLY

CED
CED
PAINTING
PAINTING

Problem
Problem point
point
PC
PC FINISH
FINISH
PAINTING
PAINTING

DESPATCH
DESPATCH

LOADING
LOADING TO
TO
DESPATCH
DESPATCH

PACKING
PACKING

STEP-4 ANALYSIS THE PROBLEM

IMPORTANCE OF THE PROBLEM

IMPORTANCE / EFFECT OF THE PROBLEM

This is a irritating potential customer


complaint at Tractor export assembly
This may also affect other product so
Wheels India brand name will lost
Wheels may have to be scrapped and
replaced

Problem Definition using 4W 1 H

By using 4W & 1H
WHAT is the Problem?

Low Torque

WHERE does this


problem occur?

Tractor Export assembly

WHEN does it occur?

Rim & Disc Assembly

WHO notice this


problem?

Inspector

HOW much is the


severity?

Production loss, Rework


cost increase.

BRAIN STORMING

p-5 Identifying the Causes


S.No

List of causes

Low air pressure

Nut Runner inconsitancy

Unskilled operator

Bolt , Nut threads worn out

Hight D

Wrong lug welding inset

Wrong Rim & Disc assembly position

Wrong position of bolt & nut

Wrong lug size

10

Wrong bolt & nut assembly

11

Wrong rim code marking

12

Wrong disc code marking

13

Incorrect Assembly fixture

TOTAL NO.OF POINTS:15

CAUSE & EFFECT DIAGRAM /FISH BONE DIAGRAM /ISHIKAWA DIAGRAM

Machine

Man

Wrong Lug welded

Wrong bolt & nut


assembly

Rim & Disc

Incorrect Assembly fixture


Wrong lug

assembly position

welding inset
Untrained person

Wrong position
of nut & bolt

Wrong disc code marking

Wrong disc supply

Wrong rim code marking


Wrong lug welding
Wrong location of
marking

Various form
depth

Wrong Lug welded rim supply

Wrong lug

Methods

Materials

NO OF
POSSIBLE
CAUSES :
13

Method For Considering Causes for Validation

CAUSE & EFFECT DIAGRAM


Ma
n

Machine

Wrong Lug welded Rim &


Disc assembly position

Wrong Assembly
Wrong Lug
welded rim
supply

Methods

Materials

NO OF
IMPORTANT
CAUSES :2

STEP 7

why why analysis


Wrong assembly
Why?
Wheels offset changed
Why?
Disc position changed
Why?
Wrong Disc

Counter measure

An arrangement to find out the offset of


flange due to Wrong assembly to be
provided

Step-8 Developing Solution


BEFORE

PROBLEM

There was no provision to


find out the wrong
assembly

AFTER

IMPROVEMENT

A flag like arrangement


provided to find the
wrong assembly

N
o

Re
si
st
a

nc

tep-9 Foreseeing Probable Resistanc

Step-10 Trial Implementation


Sl. No

Trial Date

25.07.2012 to
27.07.2012

Process /
machine /
Detail of the
trial

Export
Assembly
Wheels have
been assembled
to

No. of Qty
Trial taken

1500

Qty Accepted

1500

TRIAL
TRIALACCEPTED
ACCEPTED

Qty
Rejected

Final result

POKA YOKE
Implemented is
working in good
condition.

5W + 1 H

Standardization

-11 Regular Implementation


S. NO

WHAT

Wrong Assembly

WHY
Rim disc
assembly
offset due to
wrong part
assembly

WHO

LQA

WHERE

Export Assembly

WHEN

HOW

Aug 2012

A POKA YOKE with


sensing
arrangements have
been put in place to
identify the wrong
assembled wheels.

This POKA YOKE is added in the existing POKA YOKE Master list and being
Monitored in on daily basis.

Horizontal
Deployment
Same type of system has been planned to
Domestic Tractor Assembly

ep-12 Follow Up /Monitoring & Revie

Benefits

PDI & Customer complaints have been eliminated in Export


assembly
Rework due to wrong assembly has been eliminated.
Rework operators fatigue has been eliminated.
On time delivery
Safety issues during offline rework has been eliminated

COST BENEFITS
External Savings(Customer complaint)
Replacing cost per wheel
Total cost
Internal savings
Laabour cost per wheel
Consumable cost per person

US$=2000
INR 1,10,000
Rs.14
Rs.54

Manpower for rework

Total wheels per year

200

Total cost

Total cost saving/Year

40800

INR 1,50,800

tal cost for complete this project=Rs.5150


Total cost for complete the project

THANKS TO ALL