Process capability improvement of

turbocharger center housing component

Revanth Vinay Kumar - 16BME0262
Vishal Reddy - 16BME0731
Sherin Thomas Sipri - 16BME0751
B.Tech. Mechanical Engineering

Second Review Presentation

School
School of
of Mechanical
Mechanical Engineering
Engineering
Prof.
Prof. Sundaramali
Sundaramali G.
G. External
External Guide:
Guide: Mr.
Mr. Nathan
Nathan
Project
Project Guide
Guide Organization:
Organization: ABI
ABI Soorai
Soorai
Date
Date of
of Presentation:
Presentation: 23/05/2020
23/05/2020
Green
Green
CONTENTS

Introduction
Literature Review
Knowledge Gained
Literature gap
Objective
Methodology
Results
Conclusion

2
Introduction

• ABI Soorai Green, a division of ABI Showatech, located in

Sholinghur, is manufacturer of turbocharger components.
• The main processes that occurs in the factory is the machining of
the components which enter the factory after casting.
• ABI Soorai Green packages these components and ships them to
Borg Warner who caters to companies like Hyundai and Fiat.
• The problem that our project aims to solve is the high rejection
rate encountered in the production of the Fiat 2.2L turbocharger
center housing component.
• This project also aims to reduce the cycle time and reduce the
scrap produced.

3
Literature Review
Title of the paper Journal & Year Authors Description/Remarks
Cycle time reduction of a International S. Santhosh Kumar This paper deals with cycle time reduction by
truck body assembly in an Conference on and M.Pradeep application of lean tools and line balancing by
automobile industry by lean Advances in Kumar identification of individual process times, value
principles
Manufacturing and stream mapping and line balancing.
Materials
Engineering, AMME
2014
Application of Value 3rd International K Venkataraman, B. This paper aims at improving problems such as
Stream Mapping for Conference on Vijaya Ramnath, excessive wastage by implementation of tools like
reduction of Cycle Time in a Materials Processing V.Muthu Kumar, 3 methods of kaizen and to obtain a single flow
Machining Process and Characterization C.Elanchezian process.
(ICMPC 2014)

Using 5W-1H and 4M MATEC Web of Krzysztof Knop, This paper gives a brief description of the 4M and
methods to analyze and Conferences, 2018 Krzysztof Mielczarek 5W-1H methods to visually inspect an electrical
solve the Problem with the switch. This paper was useful to understand the
Visual Inspection Process – 4M methodology as this methodology was
case study recommended by the industry engineers.

4
Literature Review
Title of the paper Journal & Year Authors Description/Remarks
Production lessening Journal of Project Pankaj Kumar, In this paper, the lean six sigma DMAIC approach
analysis of manufacturing Management, 2019 Mahipal Singh, was used to reduce wastage in a automotive part
unit in India : Lean Six Gurpreet Singh Phull manufacturing facility.
Sigma perspective

A methodical literature Australian Journal of Amitkumar This paper, apart from describing the various six
review on application of Mechanical Dhanjibhai Makwana, sigma tools that can be implemented for our
Lean and Six Sigma in Engineering Gajanan Shankarrao project, also lists comprehensively the various
various industries Patange papers from different journals that make use of
lean principles.

Elimination of Sporadic International Journal Rateesh Nair, S.A. This paper deals with the elimination of defects in
defects in Polyurethane of Engineering Sonawane the polyurethane lining process by the
Lining Process by using Research and identification of defects using tools like pareto
Quality Maintenance Technology, 2016 chart and 4M + T method.
Methodology

5
Literature Review
Title of the paper Journal & Year Authors Description/Remarks
Application of design for Int. J. Six Sigma and Kumbhar Mahesh This paper applies the design for six sigma by
Six Sigma methodology to Competitive Suresh, applying the methodology of Identify, design,
an automotive component Advantage, Vol. 10, P. Asokan and S. Optimize and validate for an automotive seal
Vinodh
No. 1, 2016 component.

Using Six Sigma DMAIC to Procedia - Social and Monika Smętkowska, This paper deals with the detailed application of
improve the quality of Behavioral Sciences Beata Mrugalska
the production process: a the design, measure, analyze, improve and control
238 ( 2018 ) 590 – 596 phases in a company on a a machine Kolbus BF
case study
511.

The effects of tool edge CIRP Annals -
radius on drill deflection and Manufacturing
hole misalignment in deep Technology 63 (2014)
hole gundrilling of Inconel- 125–128
718
K.S. Woona, A. This paper discusses the effect of drill edge radius
Chaudhari , M. on drill misalignment leading to hole
Rahman , S. Wanc, A. misalignment especially in high length to diameter
Senthil Kumar ratios, while taking into account cutting forces,
drill deflection and wall deformation equations.

6
Literature Review
Title of the paper Journal & Year
Experimental investigation 10th CIRP conference
of clamping systems and the on Intelligence
resulting change of cutting Computaion in
conditions while drilling Manufactturing
carbon fiber reinforced Engineering – CIRP
plastics ICME ‘16
A novel approach in high Precision Engineering
performance deep hole 56 (2019) 432–437
drilling of Inconel 718
Authors Description/Remarks
Stefan Klot, Andreas This paper experiments the influence of clamping
Lepold, Fredrik systems on cutting conditions. A relationship
Zanger, Volker between deflection and axial force was
Schulze determined. They also show that cutting
conditions vary during the entire drilling process.
Afzaal Ahmed, M.T. This paper explores the effectiveness of coolant
Lew, P. Diwakar, A. pressure and rotation speed during deep hole
Senthil Kumar, M. drilling . The second phase pf the study involves
Rahman fabrication of a straight guide hole which
considerably reduces thrust force.

An analysis of the Six Int. J. Production Jeroen de Mast, Joran This paper presents comprehensively the
Sigma DMAIC method from Economics 139 (2012) Lokkerbol methodology the application of DMAIC technique
the perspective of problem 604-614 for solving problems along with its limitations.
solving

7
Knowledge Gained

• Working of Industry, how the component flows through the

factory, inspection and quality control, and packaging.
• Understood how the presence of a single defect can affect the
rejection rate of the component i.e., the scrap generated is high.
• The application of lean and Six Sigma principles such as 4M,
Pareto chart, X bar - R chart and p-chart.
• The applications of above methods to identify causes of defects,
and how to solve them, to reduce cycle time and to reduce
rejection rate.

8
Literature Gap

• One defect that our objective is to identify the root cause of and
solve is the misalignment of holes on the turbocharger housing
component.
• Since the root cause of the problem has not been identified, i.e.,
whether it is due to defect in the machine, or due to vibrations
caused due to improper clamping etc.
• The problem lies in the fact that around 70% of the components
are produced defect free so it is difficult to identify the cause of
the problem.
• We haven’t been able to find the relevant literature in this regard,
so solving this problem will help to plug the gap.

9
Objective

• To identify the cause of the defect ( Hole misalignment in the

turbocharger housing component), and solving of the identified
problem.
• To collect data on present cycle times and identify possible ways
to efficiently optimize cycle time by eliminating or reducing non
value added activities.
• To reduce the rejection rate by reducing the amount of scrap
generated by using the proper tools such as pareto chart to
identify the major scrap generating processes and then using
implementing the appropriate tools to optimize the amount of
scrap generated and therefore effectively reduce rejection rate.

10
Methodology

• After understanding of the problem and a thorough review of

literature and discussion with engineers, we decided to go
ahead with Define, Measure, Analyse, Improve and Control
(DMAIC) methodology.
• First, for the purpose of our project, we have identified the
problem as specific type and not generic type as the problem
which is going to be solved is very clear.
• Second, the categorization of this specific problem into Type
1/2/3/4 is necessary in order to proceed further.

11
Methodology
Start

Has any group

Is the process No Yes
done proper Type-2
responsible for
creating the
study before & problem
established the
problem known
reason

Yes No

No No
Are there any Are there any Type-4
known hardware
abnormalities in
known solutions problem Our Problem type
that can be
the equipment implemented
used in that
process
Yes
Yes

Type-3
Type-1 problem
problem

12
Methodology
• Since our problem falls into type 4 problem we are able to proceed with
DMAIC methodology for our project. For the other three types of problems,
only Improve and Control phases are required.
Define Phase:
• The current rejection rate in the manufacture of turbocharger center housing
component is very high and leads to high costs in the form of wastage for the
company. This rejection rate is primarily due to a hole misalignment problem
that occurs in the Makino machine which is explained in the measure phase.
• Our goal is to reduce the rejection rate to a specific target and try to work
towards that target.
• Ideally in problem solving in DMAIC, a target reduction of 80% is set. For
that reason our target is set to 7.5% from the current rate of 30%. This target is
what our project ultimately hopes to achieve.

13
Methodology

Measure Phase
• The measure phase involves the mapping of the process along with the
manufacturing stage where the problem is generated. Then, the variation in
measurement is analyzed and abnormal fluctuations in rejection rate, if any are
found. Then, this phase ends with the identification of the Suspected Sources
of Variation (SSV’s).

14
 Methodology Turning of back plate
Start side.
(Cutex)

Turning of turbine
housing side.
(Hitech)
Process map with the
problem occurrence Machining of inlet, outlet,
and detection side, and outer diameter Occurrence of
thin hole. problem
(Makino)

Machining of thrust plate

Detection of
side and VTG hole.
defect (CMM)
(HAAS)

Delivery and
End
final viewing.
 Methodology
• Part-to-part/ Time-to-time/ Stream-to-Stream Variation analysis.

16
Methodology

• Part-to-part variation – 25 microns

• Time-to-Time variation – 45.55 microns
• Stream-to-Stream variation – 92 microns

• Since highest variation is in the part-to-part, the

problem is in the machine.

• Average part-to-part variation : 44.3

• Upper control Limit = 2.575(constant) * 44.3 =
114.15 microns.
• Since all part-to-part variations lie within the
upper control limit, this confirms that the
problem is in the machine and not in the process.

17
Methodology
• Cause and Effect Diagram (Plotted on Minitab Software).

18
Methodology
• Identification of Suspected Sources of Variation

Suspected Source of Variation Type of SSV

Drill Deflection Variation SSV
Side Clamp Pressure Design SSV
Top Clamp Pressure Design SSV

• Design causes – Operational causes that will not change or vary

from part to part or time to time or batch to batch.
• Variation causes – Operational causes that can vary from part to
part or time to time or batch to batch.

19
Methodology

• Analyse Phase
• Variation SSV’s can be analysed using paired comparison method.
• Paired comparison is used when the SSV’s can be verified on good/bad parts
selected based on the required response i.e., the suspected cause can be measured
on both the accepted and rejected components, which is possible in our case,
where the drill deflection in terms of theta is known and can be verified for both
the accepted and rejected components.
• First, collect 8 Good parts and 8 Bad parts from the suspected cause.
• Then list the Good parts and Bad parts along with the corresponding column of
the values.

20
Methodology
• This table depicts how
the good and bad parts
are listed and how we
arrive at the theta value
based on hole
misalignment and total
drill depth.
• We then proceed to
arrange the values in
ascending order.

21
Methodology
• After arranging them in
ascending order, draw a line
where the first change from
bad to good occurs.

22
Methodology
• After arranging them in
ascending order, draw a line
where the first change from bad
to good occurs.
• Count the values below the line
and the values above the line.
Add them. This is the total count.
• We obtain a total count of 16.
Since this value is greater than 6,
this is a cause of the problem.

23
Methodology
• .Now, we need to determine if tool deflection is a root cause.
• Total variation from the 16 data in this data it is 0.076 microns
• Find out
• (total variation/tolerance)x100=(0.076/0.046)x100
=165.21%
• if the percentage is <= 75% then the cause is a root cause or else
it is not a root cause.
 
 

24
 Methodology
Next we can use the Variable Search method to study the involvement of side and top
clamp pressure in the rejection rate. Here, the data collection is done by trials. There
are two phases involved in this method :-
1.) Planning phase
Involves determining the design parameters, the response, the current settings and
improved settings.
2.) Data collection and analyse phase
Conducting initials trials till a difference in quality is achieved, determining the
significant and insignificant parameters, checking if the insignificant parameters have
zero contribution, conducting factorial analysis to see if the significant parameters
make a difference in quality and finally, creating an equation and finding the optimal
settings for the process.

25
Methodology

Variable Search Process

• List the design parameters based on the following guidelines.
- Parameters which can change easily in the process without incurring much cost.
- Parameters which are not hardware condition related and
- Parameters whose optimal conditions can be implemented in regular process.
• Existing condition is always the ‘-‘ setting. ‘+’ condition is the condition which is
likely to reduce the rejection (Based on experience and knowledge of the
operator), ‘+’ doesn’t mean a higher or lower value.
• For our experiment the SSV’s are Top and Side clamp pressure (unit in psi) with
the ‘-‘ and ‘+’ condition listed in the above table.
Methodology
• Produce 1 batch with all the parameters set to ‘–‘ condition.
• Then, produce 1 batch with all the parameters et to ‘+’ condition.

• We do this alternatively and make 3 batches in ‘–‘ condition and batches in ‘+’
condition

• If the application is Process optimization, produce a batch of 10 numbers. Check

all the quality parameters (responses) in all the10 parts
 
• If the response is Variable, calculate the average of 10 values and this will be
taken as the response.
Methodology
• The theme of this project is problem solving with the problem having specific
response so the batch size is calculated accordingly.
 
Batch size=(100/rejection%)
 
• Since rejection percentage is 30% the batch size is approximately 3.
 
Methodology
• Trial 1

If the D/d ratio is >= 3, conclusion is there is a difference in Quality

between the – and + setting.
Methodology
• If the D/d ratio is < 3, then check whether D/d ratio is >= 1.25 and there is no
overlap in the responses of ‘–‘ setting and ‘+’ setting, then also the there is a
difference in Quality between the’ –‘ and ‘+’ setting.
• If D/d ratio is > 1.25 and < 3, but there is a overlap in the responses of the ‘-‘ and
‘+’ setting, then there is no difference in Quality between the ‘-‘and ‘+’ setting.
• If the D/d ratio is <1.25, then there is no difference in Quality between the – and
+ setting.
•   Since the D/d ratio is < 1.25, there is no difference in quality for the first trial.
Methodology
• If there is no difference in quality, we take the ‘+’ setting as ‘-‘ setting and then we
identify new ‘+’ setting and then we do the same data calculation and D/d ratio
calculation until we get a difference in quality.
Methodology
• Trial 2

Since the D/d ratio is < 1.25 there is no difference in quality and we repeat the
process again.
Methodology
• Trial 3

Since the D/d ratio is > 1.25 and < 3 and there is no overlap in responses,
there is difference in quality between the ‘-‘ and ‘+’ setting.
Methodology
• Response plot graphed on Minitab
Methodology
• Now, we proceed to find out which parameter has contributed to the difference in
quality by interpreting a graph which we draw by following the below steps :
• Make a graph with the responses on the Y axis and indicating the ‘1st run’, ‘2nd
run’ and ‘3rd run’ on the X-axis.
• Then we find out the average of the medians from the table 6.3.2.6.
• Then we draw a horizontal line at the average value of the medians.
• We then mark the ‘-‘ and ‘+’ setting responses .
Methodology
• We then calculate the UDL and LDL for the ‘+’ and ‘-’ setting as per the formula
shown below :

•  UDL (+) = Median (+) + 1.45 x (d)

• LDL (+) = Median (+) - 1.45 x (d)
•  UDL (-) = Median (-) + 1.45 x (d)
•  LDL (-) = Median (-) - 1.45 x (d)
Methodology

Finally we draw the upper deviation line, lower deviation line and the
median in the control chart.
Methodology
• The significant parameters test

• A-R+ represents that the top clamp pressure is fixed at ‘-’ setting (ref table 6.3.2.5)
and ‘R+’ represents later parameter B is in’+’ setting vice versa for A+R- .
• B-R+ represents that the side clamp pressure is fixed at ‘-’ setting (ref table 6.3.2.5)
and ‘R+’ represents later parameter A is in ’+’ setting vice versa for A+R- .
Methodology
• Finally the significant parameters are determined from the control chart.
Methodology
We then make conclusions based on the following conditions:
• If the + line and the – line both cross the middle line, then that parameter is the
only significant parameter.
• If only one line crosses the middle line or is very close to it, then that parameter is
one of the significant parameters.
• If both the lines do not cross the middle line, then that parameter is not significant.
But whether or not it has zero contribution depends upon other criteria.
• But, for our case we get one line crossed for A and B so we can conclude that A
and B are important parameters. (Further confirmed by the fact that both lines
cross for both A&B).
Methodology
Factorial Analysis
• For this next step, this type of analysis is done only for the important parameter,
which in our case are A and B.
Methodology
• The regression equation for the response using side and top clamp pressure is
formed.
R = 5.964 – 0.06325 x A – 0.07420 x B + 0.000790 x ( A x B)
• Interaction plot between side and top clamp pressure is plotted for the response.
Methodology
• The interaction plot explains that when the side clamp pressure is 75 psi and top
clamp pressure is changed from 90psi to 95psi there is change in the mean of
response this shows that the top clamp and side clamp pressure has interaction
between them.
Interaction Plot for response
Fitted Means
top clamp pr * side clamp p side
0.040 clamp p
75.0
80.0

0.035
Mean of response

0.030

0.025

0.020

90.0 95.0
top clamp pr
Methodology
• Using this equation and by taking range of top clamp and side clamp pressure
values with the help of data tables function in ‘what if analysis’ excel function
there are different combinations of top clamp pressure and side clamp pressure
settings (ref table )
• To find the optimal response , the value of optimal response is calculated
accordingly
- response is Lower is better – USL – 2.3 x d
- response is Higher is better - LSL + 2.3 x d
- response is nominal is better - Middle 50% of tolerance
• in this project the response is nominal is better that is the tolerance of shift should
be in the range of 0 – 0.025 mm.
Methodology

• From the above table it is clear that for 3 combinations of the top clamp and side
clamp pressure the misalignment is zero they are (95psi,50psi),(95psi,55psi) and
(100psi,75psi).
Result
• From the factorial analysis three possible combinations are possible for which the
response would result in zero. Ideally it is better to take the combination of top
and side clamp pressure of (100 psi, 75 psi), as the response would be expected to
decrease from the interaction plot.
Conclusion

• The project has been completed as far as finding design changes to better produce
a lower hole misalignment error. However the outbreak of COVID-19 in India and
the subsequent closing down of industries has resulted in the halting of our
project.
• If the design changes we found are implemented by the factory, defect based
rejection would decrease, though much higher than the target we had originally
kept. This would have been followed by decrease in the scrap generated.
• Finally, the cycle time reduction objective could also have been achieved using
the principles from Six Sigma, had the factory not shut down its operations.