Process capability improvement of turbo charger center housing component

Sherin Thomas Sipri | 16BME0751 | Dr. Sundaramali G | SMEC

ABI Soorai Green a division of ABI Showatech

Motivation/ Introduction Results

In recent years, there has been a push for the adoption of Six Sigma and Lean Top and bottom clamp pressures are found to be the necessary parameters for
production methodologies by manufacturing industries in India for the purpose of the process optimization from the control chart.
competing with manufacturing centres around the world. This has led to better
productivity and quality in engineered goods. This project is the demonstration of
the power of strong data driven methods in finding problems and offering Control chart
effective solutions to remedy them. Components used in vehicles are to be of very
defect free for the safety of the consumers. This project is done to remedy the
defects found in an essential car component that can highly affect its perfomance.

SCOPE of the Project

The key objective is to find and solve the high rejection rate ABI Soorai, is facing
when it comes to its turbo charger center housing component that it sells to
Borgwagner. This project utilizes procedures from the Six Sigma method and Lean
production methods. Implementing Six Sigma methods is time consuming so it is Factorial analysis is performed for the side and top clamp pressure. From this
acceptable for the project to take time for measuring data and arriving at analysis it has been found that keeping the side clamp at 75 psi, and varying the
solutions from the inferences. Also the project duration will also depend on how
top clamp pressure from 90 to 95 psi, a regression equation can be formulated
willing and open the factory where the investigation takes place, is willing to be.
The last step of the DMAIC method implemented, won’t take place as it would go from which we can find the optimal solutions resulting in the least margin of
past the duration alloted to the project error. A what-if analysis is performed and the regression equation is used to
show the responses at various combinations of the side and top clamp pressures.

Methodology
The machining process that goes into the manufacture of turbo charger center
housing is detailed in a process map.

The problem is defined as type-4, which calls for the use DMAIC cycle from the Six
Sigma method.

What-if analysis

Turbo charger center The categorization of our Three possible combinations are found for the side and top clamp pressure i.e.
housing problem (50,95), (55,95) and (75,100). (75,100) is taken as the optimal combination as
concluded from the interaction plot.
The methodology used here is the DMAIC cycle from the Six Sigma method.
Define: 1. The rejection rate found is from the current 25% to 5%.
2. The cycle time for the process is reduced.
3. The scrap generated is reduced.
Measure: Multi-variation analysis is performed and suspected sources of
error are identified. Cause and effect diagram is plotted.
Part to part variation is found to be the highest therefore the problem exists with
 
machine rather the process.
Interaction plot

The optimum combination based on the speculation that, the deviation would
decrease as the top clamp pressure is increased from 95psi to 100psi, keeping
the side clamp pressure equal to 75 psi.

Conclusion/ Summary
The optimum clamping conditions have been found for the drilling operation of
Graph for part to part variation the turbo charger center housing component. Implementation of the clamping
Cause and effect diagram condition will result in a change in the rejection rate. This will also be followed by
scrap reduction. Further study must be conducted into whether, increase in the
Suspected sources of variation clamping pressure may result in changes in clamping design to decrease possible
increase in cycle time and surface deformation. Cycle time reduction for the
machining process of the turbo charger center housing component would have
Analyse: Paired comparison to determine the root causes from the suspected been possible by approaching the problem, using the Six Sigma approach, by
sources of variation. asking questions as to where the increased time overheads is present in the
Drill deflection found to have less effect on the rejection rate. machining process.
Variable search performed for side and top clamp pressure.
Factorial analysis performed to find the optimum values for the side and top The implementation of the changes suggested would have been possible, but for
clamp pressure. the global pandemic of COVID-19.
Contact Details
sherinthomas.sipri2016@vitstudent.ac.in
Effect of top and side clamp pressure
on rejection rate Acknowledgments/ References
My gratitude goes to ABI Soorai for providing this educational opportunity. I thank
my project coordinator Dr. Sundaramali G for arranging this project for me and my
team mates. Further wishes need to given to the Chancellor, the Dean of SMEC,
the HoD of the department of Mechanical and Production engineering for
overseeing the completion of my project.