Swaraj Engines Ltd -Mohali

Quality Circle

KANZEN

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Swaraj Engines Ltd -Mohali

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Swaraj Engines Ltd -Mohali

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OUR COMPANY

SWARAJ Engine Ltd, Mohali

 Established - 1988
 Plant Area - 14 Acres
 Production Capacity - 48000 Engines/Annum
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OUR PRODUCTS -TRACTOR ENGINES

Cylinder Head Con rod GEAR CASING

CYLINDER BLOCK CRANK CASE 3

 In Plant SML Engine’s Components

SML Cylinder Head Case transmission Housing

Connecting Rod Cylinder Block

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OUR COMPANY PRODUCTS : --

RV 3 XM + RV 2 XM +

7
RV 30 XM RB 33
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Saurabh Vig-
Facilitator

Pritam- Team
Leader

8
Himanshu Sukhwinder S Harish Ramesh Kumar
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Introduction of quality circle

Name of the Quality Circle : KANZENTHE GENIUS

Department : MACHINE SHOP
Meeting Time : Tuesday & Friday, 1:45 PM
Project Starting Date : 11/4/2011
Project Completion Date : 28/5/2011
Project Meetings : 12
Average Attendance : 87%

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STEP-1

10
1
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PROBLEM IDENTIFICATION (Brain Storming) C D

S. No. Problems

1 Cooler face unclean on III set up

2 Finishing not OK on Water pump face, Bracket face, cooler face

3 Shifting in drilling positions on cooler face

4 Mixup of RB30/33 components on III setup

5 Mixup of RB30/33 components on Milling Machine

6 Fins in inaccessible areas during fettling process

7 Dia 83 unclean problem

8 Chips come out outside of machine during boring operation

9 Lining on bottom face at milling machine

10 No Chips collection system on Milling machine

11 Hoists breakdowns problem

12 15H7 Holes unclean 12

STEP - 1
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PROBLEM IDENTIFICATION (Brain Storming) C D

S.No Problems

13 Only one Spare milling cutter available

14 Taper in coordinates on BFW II Set up

15 Milling machine hoist difficult to operate

16 No identification of cutting inserts

17 No proper arrangement for keeping inserts

18 Chips accumulation problem at reference point limit switches causes temporary breakdown of machines

19 Hoist not available on 274.02

20 Variation in Flatness of top face

21 Insert broken before the expected life span

22 MCB Tripping

23 Improper overhead lighting /poor visibility in night shift

24 Fixture stud free

STEP - 1 13
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PROBLEM IDENTIFICATION (Brain Storming) C D

S.No Problems

25 Milling Machine Overtravel

26 Hydraulic oil leakage on 493.02 from power pack

27 Air pressure low on 493.02

28 Pallet unlock problem on II setup

29 Signal illegal position

30 Frequent problem of ATC on II set up

31 Z axis down due to power trip

32 Fan not available on milling m/c

33 Ball pen not available for recording of any type of data such as spc,tpm treacebility.

34 Height variation problem on milling machine

35 Spindle oil level low

36 To Reduce the Problem of Co-ordinates shifting in Cylinder Block on II Set up

37 Leak Testing Seals problems

38 Chattering on 6deg chamfer 14

39 Step on dia 125.4
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PROBLEM IDENTIFICATION (Brain Storming) C D

S.No Problems

40 Counter face chattering

41 Drain plug unclean

42 Tapping miss

43 Core plug hole O/S

44 Dia 83 U/S

45 Hoist not available on fettling

46 Fettling lamp B/D

47 Hydraulic leakage on milling m/c

48 Dowel pin tight

49 4.15 depth taper

50 Water pump depth U/S

51 Material movement problem

52 Dent on component

53 Marker not available on milling m/c 15

54 X-axis over travel on 1009 m/c
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2
1
STEP - 2 16
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STEP - 2 17
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STRATIFICATION IN A,B,C CATEGORY C D

S.No Problems Category

1 A - Self Involvement

2 B – Involvement of other departments

3 C - Involvement of Higher Management

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STEP - 2
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STRATIFICATION IN A,B,C CATEGORY C D

S.No Problems Category

1 Cooler face unclean A
2 Finishing not OK on Water pump face, Bracket face, cooler face A
3 Shifting in drilling positions on cooler face A
4 Mixup of RB30/33 components on III setup A
5 Mixup of RB30/33 components on Milling Machine A
6 Fins in inaccessible areas during fettling process B
7 Dia 83 unclean problem B
8 Chips come out outside of machine during boring operation B
9 Lining on bottom face at milling machine A
10 No Chips collection system on Milling machine B
11 Hoists breakdowns problem B
12 15H7 Holes unclean A

A- Self Involvement
B- Involvement of Other Department’s
C- Involvement of Higher Management 19
STEP - 2
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STRATIFICATION IN A,B,C CATEGORY C D

S.No Problems Category

13 Only one Spare milling cutter available C

14 Taper in coordinates on BFW II Set up A

15 Milling machine hoist difficult to operate B

16 No proper ventilation C

17 No proper arrangement for keeping inserts A

Chips accumulation problem at reference point limit switches causes temporary breakdown of
18 machines
B

19 Hoist not available on 274.02 C

20 Variation in Flatness of top face A

21 Insert broken before the expected life span B

22 MCB Tripping B

23 Improper overhead lighting /poor visibility in night shift C

24 Fixture stud free B

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STEP - 2
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STRATIFICATION IN A,B,C CATEGORY C D

S.No Problems Category

25 Milling Machine Overtravel B

26 Hydraulic oil leakage on 493.02 from power pack B

27 Air pressure low on 493.02 B

28 Pallet unlock problem on II setup B

29 Signal illegal position B

30 Frequent problem of ATC on II set up B

31 Z axis down due to power trip B

32 Fan not available on milling m/c B

33 Ball pen not available for recording of any type of data such as spc,tpm treacebility. B

34 Height variation problem on milling machine A

35 Spindle oil level low B

36 To Reduce the Problem of Co-ordinates shifting in Cylinder Block on II Set up A

37 Leak Testing Seals problems C

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STEP - 2
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STRATIFICATION IN A,B,C CATEGORY C D

S.No Problems Category

38 Counter face chattering B

39 Drain plug U/C B

40 Tapping miss B

41 Core plug hole over size B

42 Dia 83 U/S B

43 Hoist not available on fettling B

44 Fettling lamp B/D B

45 Hydraulic leakage on milling m/c B

46 Dowel pin tight B

47 4.15 depth taper B

48 Water pump depth U/S B

49 Material movement poblem B

STEP - 2 22
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STRATIFICATION IN A,B,C CATEGORY C D

S.No Problems Category

50 Dent on component B

51 Marker not available on milling m/c B

52 X-axis over travel on 1009 m/c B

53 Chattering on 6deg chamfer B

54 Step on dia 125.4 B

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STRATIFICATION IN A,B,C CATEGORY C D

14%

32%

12 Problems

54%

B Category C Category A Category

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STEP - 2
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PROBLEM SELECTION FROM “A” CATEGORY C D

S.No ‘A’ Category Problems Importance

1 M1
Cooler face unclean
2 I
Finishing not OK on Water pump face, Bracket face, cooler face
3 Shifting in drilling positions on cooler face I

4 Mixup of RB30/33 components on III setup M1

5 M1
Mixup of RB30/33 components on Milling Machine
6 Lining on bottom face at milling machine I

7 I
15H7 Holes unclean
8 I
Taper in coordinates on BFW II Set up
9 No proper arrangement for keeping inserts LI

10 M1
Variation in Flatness of top face

11
Height variation problem on milling machine MI

12
To Reduce the Problem of Co-ordinates shifting in Cylinder Block on II Set up MI

MI – Most Important
I – Important
STEP - 2 25
LI – Least important
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PROBLEM SELECTION FROM MI “A” CATEGORY C D

Cooler face unclean

Mixup of RB30/33 components on III setup

Mixup of RB30/33 components on Milling Machine

Variation in Flatness of top face

Height variation problem on II Set up

To Reduce the Problem of Co-ordinates shifting in Cylinder Block on II Set

up

STEP - 2 26
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SELECTION OF VITAL PROBLEM C D
(Matrix data Analysis)

Problem PK RK SS HK HS TOTAL % age

Cooler face unclean 2 1 2 1 2 7 6.73

Mixup of RB30/33 components on III setup 1 2 1 2 1 7 6.73

Mixup of RB30/33 components on Milling Machine 6 5 6 5 6 28 26.92

Variation in Flatness of top face 3 4 3 4 3 17 16.34

Height variation problem on II Set up 5 3 5 3 5 21 20.19

To Reduce the Problem of Co-ordinates shifting in Cylinder Block on II

4 6 4 6 4 24 23.07
Set up

104 100

Least=1, Max=6
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STEP - 2
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SELECTION OF VITAL PROBLEM C D
(Pareto Analysis)
100 100
Chart Title 100
90 90
93.25

80 80
86.52

70 70

70.18
60 60
Axis Title

50 50
49.99
40 40

26.92
30 28 30
24
21
20 20
17

10 7 7 10

0 0
Mix up of Height variation
To Reduce Liner bore
Height Variation in Mix up of Cooler face U/C
RB30/33 on on
the milling oversize
variation flatness of top face RB30/33 on 3rd
milling Problem of problem on II setup
Co- Set up Axis Title
ordinates 28
STEP - 2
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Problem Selected :-

MILLING HEIGHT VARIATION/MODEL MIXUP

STEP - 2 29
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DEFINITION OF PROBLEM C D

STEP-3

2
1 30
STEP - 3
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STEP - 3
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DEFINITION OF PROBLEM C D

PROBLEM STATEMENT-: Variation/Model Mixup in the Milling

Height of Cy Block

BETTER BETTER
Rejection PPM Monthwise
08 Comp
7000 HOLD in one
shift
6000

5000

4000
Rejection PPM Monthwise
3000

2000

1000

0
Jan'11 Feb'11 Mar'11 Apr'11 May'11

STEP - 3 32
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MILESTONE CHART C D

WK1 (11-16 APR 11) WK2 (18-23 APR 11) WK3 (25-30 APR 11) WK4 (2-7 MAY 11) WK5 (9-14 MAY 11) WK6 (16-21 MAY 11) WK7 (23-28 MAY 11)

11 12 13 14 15 16 18 19 20 21 22 23 25 26 27 28 29 30 2 3 4 5 6 7 9 10 11 12 13 14 16 17 18 19 20 21 23 24 25 26 27 28

Defining Problem

Analysis of Problem

Listing of cause

Data
collection/Analysis
Root cause Analysis

Development of
solution
Foreseeing probable
resistance
Trial Implementation

Regular
implementation
Data
collection/comparison
Follow Up review

Presentation to
management
STEP - 3 WEEK: (1) 11/04/2011 ------ WEEK: (7) 28/05/2011 33
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PROCESS FLOW

Milling 2nd setup 3rd A setup

Washing Leak Testing Inspection

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STEP - 3
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PROCESS DEFECT
HEIGHT VARIATION IN CY BLOCK RB MODEL

IMPACT OF PROBLEM

 Degraded Quality

 Cost of Rejection to the company

 More Time In reworking if possible

 Low Productivity

 Delay in delivery

STEP - 3
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OBJECTIVES

 To Eliminate The Losses

 To Improve Quality

 To Improve Productivity

 To Reduce the cost of Bad Quality/Rejection

 To Adhere to the Assembly Plan

 To Keep the Morale high

STEP - 3 36
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GOAL TARGET
ZERO REJECTION
SETTING
35

30
DEFECTIVES PPM

25

20

15
2869 PPM
PER MONTH

10

0 0
JAN’11 to APR’11
JAN.10 TO MAY 10 MAY’11
TARGET AUG.10
STEP - 3 37
MONTH
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2
1 38
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ANALYSIS OF THE PROBLEM USING 4 W & 1 H

WHAT Milling Height Variation

WHERE On Milling Machine

WHEN During Milling Operation

WHO Process

HOW Brain Storming & Using QC Techniques

STEP - 4 40
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HOW

QC TOOLS & TECHNIQUE

STEP- 4 41
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STEP-5

3
2
42
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CAUSES OF THE PROBLEM (Brain Storming)
BLUNT INSERTS.
UNSKILL OF OPERATOR
ROCKING IN COMPONENT.
HIGH HARDNESS OF MATERIAL.
EXCESS. MATERIAL TO CUT.
UNEVEN FLATNESS OF RESTING FACE.
UNEVEN CLAMPING
CLAMIPING FORCE OF TOOL.
PULL STUD LOOSE.
DRY CUTTING.
INSERT POCKET DAMAGED.
EXCESS CUTTING RPM
PLAY IN SPINDLE.
DUST IN SPINDLE.
SPINDLE PRESSURE LESS
INSERTS NOT CHANGED
TOOL LIFE NOT DEFINED
EXCESS CUT
THICKNES VARY OF COMPONENT
LESS EXPERIENCE OF OPERATOR
CUTTING PATH OF MILLING CUTTER
CHIPS NOT CLEANED BEFORE RESTING THE COMPONENT ON FIXTURE
TOOL CLAMPING PRESSURE LESS
SPRING BROKEN OF STUD
STUD FREE
NO VISUAL CHECK BY OPERATOR
NO POKA YOKE OR CHANGEOVER PROCEDURE

STEP- 5 44
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CAUSE & EFFECT DIAGRAM CD

METHOD MAN

BLUNT INSERT
INSERT SETTING not ok EXCESS CUTTING RPM
VISUAL CHECK NOT DONE
RESTING PADS NOT IN
LEVEL
UNEVEN CLAMPING
UNSKILL OF OPERATOR
DRY CUTTING
TOOL LIFE NOT DEFINED PULL STUD LOOSE
CHANGEOVER
PROCEDURE NOT
DEIFINED Milling Height
Variation
ROCKING IN COMPONENT
EXCESS. MATERIAL TO CUT
SPRING BROKEN OF STUD
HIGH HARDNESS OF MATERIAL

UNEVEN FLATNESS OF RESTING FACE INADEQUATE CLAMIPING

FORCE OF TOOL
THICKNES VARIATION OF COMPONENT

MATERIAL MACHINE

STEP- 5 45
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REVISED CAUSE & EFFECT DIAGRAM CD

METHOD MAN

INSERT SETTING not ok

VISUAL CHECK NOT DONE
RESTING PADS NOT IN
LEVEL
UNEVEN CLAMPING
UNSKILL OF OPERATOR

PULL STUD LOOSE

CHANGEOVER
PROCEDURE NOT
DEIFINED Milling Height
Variation
EXCESS. MATERIAL TO CUT
SPRING BROKEN OF STUD

UNEVEN FLATNESS OF RESTING FACE INADEQUATE CLAMIPING

FORCE OF TOOL

MATERIAL MACHINE

46
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VALIDATION OF ROOT CAUSES CD

CHANCE ASSIGNABLE VALIDATION

S.No CAUSE DESCRIPTION
CAUSE CAUSE YES NO

1 INSERT SETTING NOT OK √ √

2 RESTING PADS NOT IN LEVEL √ √

3 CHANGEOVER PROCEDURE NOT DEIFINED √ √
4 UNEVEN CLAMPING √ √
5 PULL STUD LOOSE √ √

6 UNSKILL OF OPERATOR √

7 VISUAL CHECK NOT DONE √ √

8 EXCESS. MATERIAL TO CUT √
UNEVEN FLATNESS OF RESTING FACE
9 √

10 SPRING BROKEN OF STUD √

47
11 INADEQUATE CLAMIPING FORCE OF TOOL √
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STEP-6

6
5
4

3
2
1 48

STEP- 6
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ROOT CAUSE ANALYSIS C D

WHY WHY ANALYSIS

ROOT CAUSES WHY WHY WHY

Changeover is not required during Both Models can be run

No Change over No difference in clamping for
model change on same setting
procedure RB 30 and RB 33

Cooler face is away from

RB 30/33 Components look similar the operator during Fixture is designed and
Limited Visual Control
from Bracket face side loading the component at placed in that manner
machine

STEP- 6 50
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STEP-7

2
51
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DATA ANALYSIS OF THE CAUSES C D

MATRIX DATA ANALYSIS OF CAUSES

Sr. No. Name of causes PK RK SS HK HS TOTAL %age

Changeover Procedure
1
to be introduced
9 9 10 9 10 47 57

Visual Control to be
2
Introduced 6 8 7 8 7 36 43

Scoring- 0 to 10
0 – Least Impact & 10 – Max Impact
STEP- 7 53
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SELECTION OF VITAL CAUSE C D

MOST VITAL CAUSES IDENTIFIED

1. A Changeover Procedure to be Introduced

for Cy Block Model Mix up Rejection

2. A Visual Control to be Introduced

STEP- 7 54
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STEP-8

2
55
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DEVELOPMENT OF SOLUTION
BRAIN STORMING FOR SOLUTION

Probable
Solutions

To introduce a
Changeover system to
Visual Control
avoid Model Mix up
rejection

STEP- 8 55
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VALIDATION FOR SOLUTION C D

Ideas Accept:

(1) To Introduce a Changeover System to avoid model

mixup rejection
Solution : A new clamp has been introduced at cooler face which
locates at the cooler plate position and fouls at the other model. The
location of the clamp has to be changed everytime during model
changeover

STEP- 8 58
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DEVELOPMENT SOLUTION

SOLUTION IMPLEMENTATION – ACTION PLAN

(2) Visual Control

Solution : The milling fixture has been rotated so that the cooler
face is in front of the operator

STEP- 8 59
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DEVELOPMENT OF SOLUTION

COST OF IMPLEMENTATION

Rs. 300 Approx

This is just the cost of machining on the
fixture for repositioning of the studs

STEP- 8 60
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STEP-9

2
STEP- 9 61
1
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STEP-9 62
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DEVELOPMENT OF SOLUTION C D

RESISTANCE & SOLUTION

S.NO RESISTANCE SOLUTION RESPONSIBILITY

Fixture to be modified for
1 Discussion & Support with
New Clamps.
Industrial engineering Ramesh Kumar
2 Fixture to be rotated. deptt. And Tool Room

Operator educated and

convinced after realising
3 Operator mind set Pritam
the benefits of eliminated
reworking and Rejection.
Other department not To motivate the
4 Himanshu
interested. department.

When m/c breakdown after

5 Production losses. Harish
fixture implementation.

STEP-9 63
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STEP-10

10

2
STEP-10 64
1
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STEP-10 65
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TRIAL IMPLEMENTATION-16th May to 20th May C D

The Fixture was rotated 180 Degrees and a new clamp on the
cooler face was installed.

The Trial Was Conducted between 16.5.11 to 20.5.11 and no

Rework/Rejection was reported

STEP- 10 66
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TRIAL IMPLEMENTATION-16th May to 20th May C D

Trial From 16th May- 20th May

140
120 121 120 122
117
120
Production

100

80

60 Production
40

20
0 0 0 0 0 Rejection
0
1 6 /M a y/1 1

1 7 /M a y/1 1

1 8 /M a y/1 1

1 9 /M a y/1 1

2 0 /M a y/1 1
Days
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Before After

STEP-10 67
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Rejection PPM

3087
7

6
DEFECTIVES PPM

4
1996
3

0 0 0 0
WEEK 1 WEEK 2 WEEK 3 WEEK 4 WEEK 5
MAY

WEEKS Of The Month May 2011

STEP-10 68
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STEP-11

11

10

2
STEP-11 69
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REGULAR IMPLEMENTATION – ACTION PLAN C D

The modified Clamping with the rotated fixture is running

effectively and efficiently on Milling Machine No. 274.03

STEP- 11 71
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PLAN VS ACTUAL C D

WK1 (11-16 APR 11) WK2 (18-23 APR 11) WK3 (25-30 APR 11) WK4 (2-7 MAY 11) WK5 (9-14 MAY 11) WK6 (16-21 MAY 11) WK7 (23-28 MAY 11)

11 12 13 14 15 16 18 19 20 21 22 23 25 26 27 28 29 30 2 3 4 5 6 7 9 10 11 12 13 14 16 17 18 19 20 21 23 24 25 26 27 28

Defining Problem

Analysis of Problem

Listing of cause

Data
collection/Analysis
Root cause Analysis

Development of
solution
Foreseeing probable
resistance
Trial Implementation

Regular
implementation
Data
collection/comparison
Follow Up review

Presentation to
management
STEP - 3 73
PLAN ACTUAL
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STEP- 11 73
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TANGIBLE BENEFITS

No investment was done.

TOTAL 08 NOS OF COMPONENTS REJECTED IN LAST 4 MONTHS

ONE COMPONENTS COSTS Rs 3851/-

TOTAL REJECTION COST IS Rs 30808/-

THIS IS THE REJECTION COST FOR 4
MONTHS

AVERAGE ANNUAL SAVING IS RS 92424/-

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INTANGIBLE BENEFITS
•Elimination in Rework

• Reduction in Cy Block Rejection

•Increase in Productivity

• Increased Morale

•Increase in efficiency

• Increased per shift production due to 3 point clamping system

• Better Output due to controlled Rejection

75
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THE JOURNEY WILL CONTINUE WITH

OUR NEXT PROJECT:-

To Reduce the Problem of Co-ordinates

shifting in Cylinder Block on II Set up
75
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Manufacturing Management Process
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QUERIES/FEEDBACK C D

We Would Appreciate any

Queries or Suggestions
from your end
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