PROJECT:

REDUCE COMPONENT BENDING PROBLEM IN

TM CASE YC5 R PETROL.
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Voice of the Customer-VOC

Critical to Quality-
Customer Comments
CTQ’s

Percentage material rejection of Tm

Mr . Sahil Behal
case YC5 R model has been increased Material Rejection
(Sr. Mgr. QA/PI)
from last 5 months.

No of unclean and distortion in

Mr. Kitagava Component bending and Distortion
component Increased drastically
(SMC Advisor) in component.
from last 5 months

Due to high rejection rate at

Mr. Sachin SAxena
machining stage, enable to fulfil the Percentage material rejection
(Dy. Manager Production)
assembly requirements
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R PROJECT CHARTER
Business Case:
M/s MARUTI SUZUKI INDIA Ltd. MP unit In Scope:
(ISO/TS16949) is a manufacturer of engine and
Tm case YC5 R Casting Machines of Casting plant
transmission units for MARUTI SUZUKI INDIA Ltd. It and Tm case YC5 R machining lines.
was reported by the QA/PI dept. of the MARUTI SUZUKI
INDIA Ltd. that after Jan./2013 Rejection of Tm case
Out of Scope:
YC5 R model has been increased drastically due to
.All other Casting machines and Machining lines
which machine shop and assembly lines area enable to
achieve the desired production target.

Problem Statement: High Level Project Plan

In Jan./2013 to April./2013 total Tm case YC5 R Target Date Actual Date

machined 125808 nos. and Total material rejected parts Start Date 20/04/13 20/04/13
are 5278 nos. due to bending or distortion only. Bending
Define 25/04/13 23/04/13
value has been found upto 1mm against target 0.6 mm.
Measure 5/05/13 5/05/13
Hence percentage rejection of Tm case YC5 R has
gone up by 4.19% against the target of 2%. which is Analyze 15/05/13 16/05/13

increasing the cost of poor quality. Total lose of Improve 29/05/13 1/06/13
money by rejected parts has gone up to Control 10/06/13 12/06/13
Rs.14500000 in just 5 months.
Goal Statement:
Reduce the distortion value of the component upto
0.6mm by 10-Jun-13.
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R ARMI AND COMMUNICATION PLAN
Key ARMI Worksheet
Stakeholders Define Measure Analyze Improve Control

Plant Manager I I I I I

Production Head I I I I I
Production Mgr. I&A I&A I&A I&A I&A
Sr. Mgr. QA/PI A&I A&I A&I A&I A&I
BB I&M I&M I&M I&M I&M
Model Incharge I&R I&R I&R I&R I&R
Line Supervisors R&M R&M R&M R&M R&M
Team Members M M M M M

Communication Plan
Information Or Activity Target Audience Information Channel Who When
Project Status Leadership E-mails Mahesh BI-Weekly

Tollgate Review BB,LBB,MBB & E-mails or Meetings Mahesh As per Project Plan
Champion
Project Deliverables or Members Emails, Meetings Mahesh Weekly
Activities

A – Approval of team decisions I.e., sponsor, business leader, MBB.

R – Resource to the team, one whose expertise, skills, may be needed on an ad-hoc basis.
M – Member of team – whose expertise will be needed on a regular basis.
I – Interested party, one who will need to be kept informed on direction, findings.
PROJECT: REDUCE

RASIC
MACHINING REJECTION OF
Tm case YC5 R
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R SIPOC

INGOTS - ADC12

Receipt inspection of raw

material Aluminum ingot
ADC-12

Raw material composition

.inspection

Melting

Nitrogen purging (GBF)

Metal transfer in holding

Furnace

RAW Casting

PPC MATERIAL FINISH Tm MACHINING

Deburring & Inspection
STORAGE (Aluminum) case YC5 R LINES
QC Inspection
AREA CASTING
Packing ( component in
trolley)& dispatch PARTS
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Data Collection Plan
Y Operational Defect Performance Specification Opportunity
Definition Definition Standard Limit

Distortion The difference of the If the distortion or Distortion value must LSL= 0, Per Part
in Tm case min. and max. plan at bending value is be under 0.6mm
YC5 R fix die face of tm case 0.6mm or more, it is USL= 0.6mm
YC5 R is Distortion or defect.
comp. bending value.

Mode of collecting Data

Existing or If New when Plan start
Data Base
new data data base date for
Container
Decimal to base would be DCP
Y Data Type Unit
be Used ready.
Distortion in Continuous mm 3 Excel Existing - -
Tm case YC5 R

Equipment Equipment Any

Operator
Used for Calibration Responsibility Training
Information
measurement Information need
Dial Gauge, Calibrated Vinod N/A Kailash,
Height Gauge, Manish,
CMM Ramesh
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Gauge R&R for Dial Gauge
RESULT

1.Contribution of Gage R&R=0.09%

Contribution of Part to Part=99.91%
2. % Contribution of gage R&R=6.73%.
3. Numbers of distinct categories=45.

RULES
1.Contribution of Gage R&R should be less then Part-to-Part.
2.Percentage contribution of Gauge R&R against Equipment Tol.
i)Less than 10%- Good
ii)Between 10% to 30 %- OK, Proceed with Caution.
iii)Greater than 30%- Reject.
3. Numbers of distinct categories should be equal or greater than 4.
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Gauge R&R for Height Gauge
RESULT

1.Contribution of Gage R&R=0.45%

Contribution of Part to Part=99.45%
2. % Contribution of gage R&R=6.73%.
3. Numbers of distinct categories=20

RULES
1.Contribution of Gage R&R should be less then Part-to-Part.
2.Percentage contribution of Gauge R&R against Equipment Tol.
i)Less than 10%- Good
ii)Between 10% to 30 %- OK, Proceed with Caution.
iii)Greater than 30%- Reject.
3. Numbers of distinct categories should be equal or greater than 4.
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Gauge R&R for CMM
RESULT

1.Contribution of Gage R&R=0.92%

Contribution of Part to Part=99.08%
2. % Contribution of gage R&R=9.61%.
3. Numbers of distinct categories=14

RULES
1.Contribution of Gage R&R should be less then Part-to-Part.
2.Percentage contribution of Gauge R&R against Equipment Tol.
i)Less than 10%- Good
ii)Between 10% to 30 %- OK, Proceed with Caution.
iii)Greater than 30%- Reject.
3. Numbers of distinct categories should be equal or greater than 4.
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R
ACCURACY CALCULATION FOR MEASURING
INSTRIMENTS
ACCURACY CALCULATION FOR MEASURING INSTRUMENTS. RESULT

Measurement in 1.BIAS for Dial Gauge= -0.002mm,

Measurement in mm with
mm 2.Bias for Height Gauge=-0.003mm
3.BIAS for CMM=-0.001
MASTER HEIGHT DIAL GAUGE HEIGHT GAUGE CMM
20.021 20.001 20.001
19.997 19.999 19.997 Accuracy with our measuring
instrument are OK as per our
20.002 20.004 20.002 requirements.
20.003 20.005 20.003
20.004 20.006 20.004
19.997 19.999 19.997
19.998 20.000 19.998
19.999 20.001 19.999
20.003 20.005 20.003
20 20.004 20.006 20.004
20.006 20.008 20.006
19.998 20.000 19.998
19.999 20.001 19.999
20.001 20.003 20.001
20.004 20.006 20.004
20.003 20.005 20.003
19.997 19.999 19.997
19.995 19.997 19.995
20.005 20.007 20.005
AVERAGRE 20.002 20.003 20.001
BIAS -0.002 -0.003 -0.001
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Current Performance Level

PARTS MACHINED: 125808 (from Jan.13 to April.13)

TOTAL NG PARTS: 5278 (from Jan.13 to April.13)

% REJECTION OCCURRED : 5278/125808*100= 4.19

PPM OF CURRENT PROCESS: 4.19*10000= 41900

SIGMA SCORE: 3.23

PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Graphical Summary of data

Data Type is Non-Normal (p-Value<0.005), Hence Measure for centre tendency in Median which is: 0.487
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Data behavior analysis

Data shows that it have Mixture behavior means no Clustering.

PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Data Normality test

P value is <0.05, hence data type is not normal

PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Cause and Effect Analysis
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Test of Equal Variance for Operator
Y TYPE X (MAN) TYPE TEST TO BE DONE
OPERAOR DISC. Leven's
AGE CONT. Correlation & Regression
DISTORTION CONTINUOUS & NOT NORMAL EXPERIENCE CONT. Correlation & Regression
SUPERVISOR DISC. Leven's
SKILL SCORE DISC. Leven's

P-value = 0.197, null hypothesis, means there is no impact of operator on distortion.

PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R
Correlation Regression testing for Distortion and
Operator Age.
Y TYPE X (MAN) TYPE TEST TO BE DONE
OPERAOR DISC. Leven's
AGE CONT. Correlation & Regression
DISTORTION CONTINUOUS & NOT NORMAL EXPERIENCE CONT. Correlation & Regression
SUPERVISOR DISC. Leven's
SKILL SCORE DISC. Leven's

Correlations: DISTORTION, AGE

Pearson correlation of DISTORTION and AGE = -0.094

P-Value = 0.036

Regression Analysis: DISTORTION versus AGE

The regression equation is

DISTORTION = 0.960 - 0.0136 AGE

Predictor Coef SE Coef T P

Constant 0.9600 0.1992 4.82 0.000
AGE -0.013625 0.006471 -2.11 0.036

S = 0.214011 R-Sq = 0.9% R-Sq(adj) = 0.7%

P-value = 0.036, alternate hypothesis, but Regression R-Sq=0.9% means a very weak relation, hence there is no
impact of operators age on distortion.
PROJECT: REDUCE
MACHINING REJECTION OF Correlation test for Distortion and Operator
Tm case YC5 R
Experience.
Y TYPE X (MAN) TYPE TEST TO BE DONE
OPERAOR DISC. Leven's
AGE CONT. Correlation & Regression
DISTORTION CONTINUOUS & NOT NORMAL EXPERIENCE CONT. Correlation & Regression
SUPERVISOR DISC. Leven's
SKILL SCORE DISC. Leven's

Correlations: DISTORTION, EXPERIENCE

Pearson correlation of DISTORTION and EXPERIENCE = -0.159

P-Value = 0.000

Régression Analysais: DISTORTION versus EXPERIENCE

The regression equation is

DISTORTION = 0.662 - 0.0230 EXPERIENCE

Predictor Coef SE Coef T P

Constant 0.66181 0.03500 18.91 0.000
EXPERIENCE -0.023001 0.006418 -3.58 0.000

S = 0.212242 R-Sq = 2.5% R-Sq(adj) = 2.3%

P-value = 0.00, alternate hypothesis, but Regression R-Sq=2.5% means a very weak relation, hence there is no impact of
operators experience on distortion.
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R
Test of Equal Variance for
Supervisor
Y TYPE X (MAN) TYPE TEST TO BE DONE
OPERAOR DISC. Leven's
AGE CONT. Correlation & Regression
DISTORTION CONTINUOUS & NOT NORMAL EXPERIENCE CONT. Correlation & Regression
SUPERVISOR DISC. Leven's
SKILL SCORE DISC. Leven's

P-value = 0.197, null hypothesis, means there is no impact of supervisor on distortion.

PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Test of Equal Variance for Operator’s Skill
Y TYPE X (MAN) TYPE TEST TO BE DONE
OPERAOR DISC. Leven's
AGE CONT. Correlation & Regression
DISTORTION CONTINUOUS & NOT NORMAL EXPERIENCE CONT. Correlation & Regression
SUPERVISOR DISC. Leven's
SKILL SCORE DISC. Leven's

P-value = 0.197, null hypothesis, means there is no impact of Operator’s Skills on distortion.
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R
Correlation Regression testing for Distortion and
Die Temp.
Y TYPE X (MACHINE) TYPE TEST TO BE DONE
DIE TEMP. CONT. Correlation & Regression
CONTINUOUS & NOT CASTING PRESSURE CONT. Correlation & Regression
DISTORTION
NORMAL METAL TEMP. CONT. Correlation & Regression
COOLING TIME CONT. Correlation & Regression

Correlations: DISTORTION, DIE TEMP.

Pearson correlation of DISTORTION and DIE TEMP. = 0.846

P-Value = 0.000

Regression Analysis: DISTORTION versus DIE TEMP.

Predictor Coef SE Coef T P

Constant -1.59798 0.06078 -26.29 0.000
DIE TEMP. 0.0098539 0.0002790 35.32 0.000

S = 0.114749 R-Sq = 71.5% R-Sq(adj) = 71.5%

P-value = 0.00, alternate hypothesis, and Regression R- Test shows that Die temp. has significant impact
Sq=71.5% means a very strong impact, and pearson on component distortion, with Scatter plot We
correlation=0.846 shows a positive relation. can see all parts produced with 200~210.C of die
temp. have distortion value under 0.6mm.
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R
Correlation Regression testing for Distortion and
Casting Pressure.
Y TYPE X (MACHINE) TYPE TEST TO BE DONE
DIE TEMP. CONT. Correlation & Regression
CONTINUOUS & NOT CASTING PRESSURE CONT. Correlation & Regression
DISTORTION
NORMAL METAL TEMP. CONT. Correlation & Regression
COOLING TIME CONT. Correlation & Regression
Correlations: DISTORTION, CASTING PRESSURE

Pearson correlation of DISTORTION and CASTING

PRESSURE = -0.002
P-Value = 0.971

Regression Analysis: DISTORTION versus CASTING

PRESSURE

Predictor Coef SE Coef T P

Constant 0.54217 0.01539 35.24 0.000
CASTING PRESSURE -0.0000060 0.0001620 -0.04 0.971

S = 0.215614 R-Sq = 0.0% R-Sq(adj) = 0.0%

P-value = 0.971, null hypothesis, hence no impact of casting pressure on distortion.

PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R
Correlation Regression testing for Distortion and
Metal Temp.
Y TYPE X (MACHINE) TYPE TEST TO BE DONE
DIE TEMP. CONT. Correlation & Regression
CONTINUOUS & NOT CASTING PRESSURE CONT. Correlation & Regression
DISTORTION
NORMAL METAL TEMP. CONT. Correlation & Regression
COOLING TIME CONT. Correlation & Regression

Correlations: DISTORTION, METAL TEMP.

Pearson correlation of DISTORTION and METAL TEMP. =

-0.041
P-Value = 0.357

Regression Analysis: DISTORTION versus METAL TEMP.

Predictor Coef SE Coef T P

Constant 0.55787 0.02027 27.53 0.000
METAL TEMP. -0.00002429 0.00002637 -0.92 0.357

S = 0.214822 R-Sq = 0.2% R-Sq(adj) = 0.0%

P-value = 0.357, null hypothesis, hence no impact of Metal Temp. on distortion.

PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R
Correlation Regression testing for Distortion and
Die Cooling Time.`
Y TYPE X (MACHINE) TYPE TEST TO BE DONE
DIE TEMP. CONT. Correlation & Regression
CONTINUOUS & NOT CASTING PRESSURE CONT. Correlation & Regression
DISTORTION
NORMAL METAL TEMP. CONT. Correlation & Regression
COOLING TIME CONT. Correlation & Regression

Correlations: DISTORTION, COOLING TIME

Pearson correlation of DISTORTION and COOLING TIME =

0.846
P-Value = 0.0

Regression Analysis: DISTORTION versus COOLING TIME

Predictor Coef SE Coef T P

Constant -1.59691 0.06070 -26.31 0.000
COOLING TIME 0.196990 0.005572 35.35 0.000

S = 0.114662 R-Sq = 71.5% R-Sq(adj) = 71.5

Test shows that Cooling time has significant impact on

P-value = 0.00, alternate hypothesis, and Regression R- component distortion, with Scatter plot We can see all
Sq=71.5% means a very strong impact, and pearson
correlation=0.846 shows a positive relation. parts produced with 9~11 sec. of cooling time have
distortion value under 0.6mm.
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R
Test of Equal variance for Distortion and Gate
cutting method.
Y TYPE X (METHODS) TYPE TEST TO BE DONE
CONTINUOUS & NOT
DISTORTION METHODS (1,2,3,4) DISC.
NORMAL Leven's

P-value = 0.187, Null hypothesis, hence there is no impact of Gate cutting method on Distortion..
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Test of Equal Variance for Si% in Material
Y TYPE X (MATERIAL) TYPE TEST TO BE DONE
Si% DISC. Leven's
CONTINUOUS & NOT
DISTORTION Fe% DISC. Leven's
NORMAL
Cu% DISC. Leven's

LEVENS TEST FOR Si% AND DISTORTION

Bartlett's Test
10.0~10.5 Test Statistic 241.09
P-Value 0.000
Levene's Test
Test Statistic 97.64
10.5~11
Si% (10%~12%)

P-Value 0.000

11.0~11.5

11.5~12

11.56

0.02 0.04 0.06 0.08 0.10 0.12 0.14

95% Bonferroni Confidence Intervals for StDevs

Test shows that Si% has significant impact on

P-value = 0.0, Alternate hypothesis, hence there is impact component distortion, with Scatter plot We can see all
of Si% on distortion. parts produced with 2~4 (Si%=10.5~12%) of Si have
distortion value under 0.6mm.
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Test of Equal Variance for Fe% in Material
Y TYPE X (MATERIAL) TYPE TEST TO BE DONE
Si% DISC. Leven's
CONTINUOUS & NOT
DISTORTION Fe% DISC. Leven's
NORMAL
Cu% DISC. Leven's

LEVENS TEST FOR Fe% AND DISTORTION

Bartlett's Test

0.7~0.75 Test Statistic 1.96

P-Value 0.580
Levene's Test
Test Statistic 0.50
Fe% (0.7%~0.9%)

P-Value 0.683
0.75~0.8

0.8~0.85

0.85~0.9

0.16 0.18 0.20 0.22 0.24 0.26

95% Bonferroni Confidence Intervals for StDevs

P-value = 0.683, Null hypothesis, hence there is no impact of Fe% on distortion.

PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Test of Equal Variance for Cu% in Material
Y TYPE X (MATERIAL) TYPE TEST TO BE DONE
Si% DISC. Leven's
CONTINUOUS & NOT
DISTORTION Fe% DISC. Leven's
NORMAL
Cu% DISC. Leven's

LEVENS TEST FOR Cu% AND DISTORTION

Bartlett's Test

0.2~0.25 Test Statistic 1.65

P-Value 0.648
Lev ene's Test
Test Statistic 1.10
Cu% (0.2%~0.4%)

P-Value 0.350
0.25~0.3

0.3~0.35

0.35~0.4

0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 0.26 0.27
95% Bonferroni Confidence Intervals for StDevs

P-value = 0.350, Null hypothesis, hence there is no impact of Cu% on distortion.

PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R
Correlation Regression testing for Distortion and
Plant Temp.
Y TYPE X (ENVIRONMENT) TYPE TEST TO BE DONE
CONTINUOUS & NOT PLANT TEMP. CONT. Correlation & Regression
DISTORTION
NORMAL SHIFT CONT. Correlation & Regression

Correlations: DISTORTION, PLANT TEMP.

Pearson correlation of DISTORTION and PLANT TEMP. =

-0.026
P-Value = 0.560

Regression Analysis: DISTORTION versus PLANT TEMP.

Predictor Coef SE Coef T P
Constant 0.55729 0.02606 21.39 0.000
PLANT TEMP. -0.0004295 0.0007369 -0.58 0.560

S = 0.215482 R-Sq = 0.1% R-Sq(adj) = 0.0%

P-value = 0.560, null hypothesis, hence no impact of plant temp. on distortion.

PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Test of Equal Variance for Shift of production

Y TYPE X (ENVIRONMENT) TYPE TEST TO BE DONE

CONTINUOUS & NOT PLANT TEMP. CONT. Correlation & Regression
DISTORTION
NORMAL SHIFT CONT. Correlation & Regression

P-value = 0.309, null hypothesis, hence no impact of shift on distortion.

PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Test of Equal Variance for Inspector
Y TYPE X (MEASUREMENT) TYPE TEST TO BE DONE
INSPECTOR DISC. Leven's
CONTINUOUS & NOT
DISTORTION ROOM TEMP. CONT. Correlation & Regression
NORMAL
GAUGE/ INSTRUMENT DISC. Leven's

P-value = 0.247, null hypothesis, hence no impact of Operator on distortion.

PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R
Correlation Regression testing for Distortion and
Inspection room Temp.
Y TYPE X (MEASUREMENT) TYPE TEST TO BE DONE
OPERATOR DISC. Leven's
CONTINUOUS & NOT
DISTORTION ROOM TEMP. CONT. Correlation & Regression
NORMAL
GAUGE/ INSTRUMENT DISC. Leven's

Correlations: DISTORTION, LAB TEMP.

Pearson correlation of DISTORTION and LAB TEMP. =

0.065
P-Value = 0.144

Regression Analysis: DISTORTION versus PLANT TEMP.

Predictor Coef SE Coef T P
Constant 0.55729 0.02606 21.39 0.000
PLANT TEMP. -0.0004295 0.0007369 -0.58 0.560

S = 0.215482 R-Sq = 0.1% R-Sq(adj) = 0.0%

P-value = 0.144, null hypothesis, hence no impact of Room Temp. on distortion.

PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Test of Equal Variance for Measuring Instruments

Y TYPE X (MEASUREMENT) TYPE TEST TO BE DONE

OPERATOR DISC. Leven's
CONTINUOUS & NOT
DISTORTION ROOM TEMP. CONT. Correlation & Regression
NORMAL
GAUGE/ INSTRUMENT DISC. Leven's

P-value = 0.275, null hypothesis, hence no impact of Gauge/Instrument on distortion.

PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Test Summary
Y TYPE X (MAN) TYPE TEST DONE HYPOTHYSIS REMARKS
OPERAOR DISC. Leven's NULL  
AGE CONT. Correlation & Regression ALTERNATE As R. Sq. value is 2.5%
max. hence these X
CONTINUOUS & NOT doesn't have any
DISTORTION EXPERIENCE CONT. Correlation & Regression ALTERNATE
NORMAL significant impact on Y
SUPERVISOR DISC. Leven's NULL  
SKILL SCORE DISC. Leven's NULL  
Y TYPE X (MACHINE) TYPE TEST DONE HYPOTHYSIS REMARKS
DIE TEMP. CONT. Correlation & Regression ALTERNATE  

CONTINUOUS & NOT CASTING PRESSURE CONT. Correlation & Regression NULL
 
DISTORTION
NORMAL
METAL TEMP. CONT. Correlation & Regression NULL  
COOLING TIME CONT. Correlation & Regression ALTERNATE  
Y TYPE X (METHODS) TYPE TEST TO BE DONE HYPOTHYSIS REMARKS
CONTINUOUS & NOT
DISTORTION METHODS (1,2,3,4) DISC. Leven's NULL
NORMAL  
Y TYPE X (MATERIAL) TYPE TEST DONE HYPOTHYSIS REMARKS
Si% DISC. Leven's ALTERNATE  
CONTINUOUS & NOT
DISTORTION Fe% DISC. Leven's NULL  
NORMAL
Cu% DISC. Leven's NULL  
Y TYPE X (ENVIRONMENT) TYPE TEST DONE HYPOTHYSIS
REMARKS
CONTINUOUS & NOT PLANT TEMP. CONT. Correlation & Regression NULL  
DISTORTION
NORMAL SHIFT CONT. Correlation & Regression NULL  
Y TYPE X (MEASUREMENT) TYPE TEST DONE HYPOTHYSIS
REMARKS
INSPECTOR DISC. Leven's NULL  
CONTINUOUS & NOT ROOM TEMP. CONT. Correlation & Regression NULL
DISTORTION  
NORMAL
GAUGE/
DISC. Leven's NULL
INSTRUMENT  
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R
 PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R QFD chart for controlling Distortion
TO CONTROL DISTORTION

CTQ RANGE (-3 ~ +3)

FACTORS RATING  
(1~5) C1 C2 C3 C4 C5 C6 Si1 Si2 D1 D2
Cooling
5 3 3 2 1 2 1 0 0 0 0 60
time
SI% 4 1 1 1 1 0 0 3 3 1 1 48
Die
5 3 3 2 1 2 1 0 0 1 1 70
Temp.
  34 34 24 14 20 10 12 12 9 9  

C1: controlling Water Temp.

C2: Auto cooling timer installation.
C3: Periodic cleaning of cooling lines
C4: Chemical reagent for improving cooling efficiency of water
C5:cooling water pipes isolation
C6: thermo couple for water temp. monitoring
Si1: changing limit of Si, from 10%~12% to 11.3% to 12%
Si2: checking of Composition of after every heat loading
D1: Die temp. indicator installation
D2: periodic inspection
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R FMEA
Severity Occurrence Detection
Actionable RPN (Risk RMS (Risk Management RTP (Risk Treatment
Sl. No. Failure Mode Effect Responsibility Start Date End Date
Items Priority No.) Strategy) Plan)
(1-10) (1-10) (1-10)

Temp. gauge installation

Variation in Variation in comp.
7 2 5 70 Reduce and shift wise recording of P.E 2/6/2013 20/06/13
Environment temp. distortion
storage water temp.

Controlling of monitoring of
1 Cooling Water Malfunction of Cooling Distortion and scoring
7 4 5 140 Reduce thermocouple condition P.E 5/6/2013 10/6/2013
Temp. unit in comp.
weekly.

Variation in comp.
Dirty cooling water 7 2 5 70 Reduce Weekly audit by prod. Mgr. Prod. 3/6/2013 5/6/2013
distortion

Auto cooling Temp. gauge installation

Variation of input water
2 Timer High distortion in comp. 7 3 5 105 Reduce and shift wise recording of P.E 2/6/2013 20/06/13
temp.
installation storage water temp.

Periodic cooling pipes wear out

High distortion in comp.
3 cleaning of 7 2 5 70 Reduce Weekly audit by prod. Mgr. Prod. 3/6/2013 5/6/2013
and die breakdown
cooling lines
cooling pipes leakage

Cooling water excess cooling of water

4 die sticking 5 1 4 20  Accept        
pipes isolation or pipes

Chemical
reagent for
rusting of cooling pipes,
improving
5 or reaction with copper cooling pipes leakage 4 1 7 28  Accept        
cooling
cooling pipes
efficiency of
water

changing limit
of Si, from Inspection error on
6 Distortion in comp. 7 2 5 70
10%~12% to Spectrometer
11.3% to 12% Verification and
comparison of Spectro
Reduce Q.C 3/6/2013 5/6/2013
primary sample in every A
checking shift starting
Composition
Inspection error on
7 of material Distortion in comp. 7 2 5 70
Spectrometer
after every
heat loading

thermo couple
for water Thermo couple
8 Water temp. variation 3 3 2 18  Accept        
temp. malfunction
monitoring

Die temp.
Thermo couple
9 indicator wrong monitoring 2 2 2 8  Accept        
malfunction
installation

periodic
10 inspection for Operator error Wrong monitoring 2 2 2 8  Accept        
Die Temp.
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R I-MR Chart for Pre & Post Improvement Distortion Data
PRE- IMPROVEMENT

POST IMPROVEMENT
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Graphical Summary of Pre & Post Improvement

Pre- improvement Post- improvement

PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Area plot for Pre & Post Distortion Data
PROJECT: REDUCE
MACHINING REJECTION OF
Tm case YC5 R Box plot for Pre & Post Distortion Data