REVIEW

PRESENTATION

G.Pranay Teja
Engineer
R&D
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 TRAININGS UNDERGONE

 Company profile and plant visit

 Product awareness/service and vehicle preparation

 Company policy framework

 Integrated management system (IMS)

 Seven quality control tools

 SAP awareness

 Lotus notes

 DNJP introductory module

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  DWM
 MARUTI PTRODUCTION SYSTEM
 KRA AND GOAL SETTING
 CAD/PLM

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 CONDENSER LINE
PROCESS FLOW:
1. Material receiving & inspection
2. Bracket assembly &plate insertion
3. Shroud assembly & packing fixing
4. Shroud sub assembly insulator & O ring assembly in tube discharge
5. Tube discharge and tank receiver assembly with core
6. Pressure switch and tank receiver sub assembly
7. Clamp assembly & packing fixing
8. DLT & packing fixing
9. Fan rotation check &Final inspection
10.Packaging
11.Move to store

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 TYPES OF MODELS
LINE 1
1. BS4
2. DLE/DLS
3. DLX

LINE 2
1. Model U Big
2. X1 TCIC step 4
3. Safari merlin
4. SUV
5. X1 fiat fire
6. Sprint 2.2 ltr LHD
7. Sprint 2.2 ltr RHD
8. Sprint 3 ltr LHD
9. Sprint 3 ltr RHD

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 DLT
 N2 pressure- 8bar
 Charging 32 sec
 Balancing time 5sec (±54 pa)
 Detection time 5sec (±18 Pa)
 Exhaust time 2sec
 Charging pressure 0.735-0.82MPa
 Main pressure 4-6 bar
 Differential leak rate +18 to -18 Pa/s
 Pressure switch continuity

Fan rotation test (40sec)

 Current 6-11 Amps
 Voltage 11.8-12.2 V DC

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 Case Study : tube damage in tcic step 4
Team Formation : Mr G.Pranay Teja ( Team Leader)
Mr Promod Kumar ( Team Member)
Mr Surjit Dash (Team Member)
Mr Ravinder Nagare ( Facilitator)

Problem Description :
there was a lot of rejections due to tube damage in condenser core and it
created a confusion whether the damage is occuring inside or outside the
plant.

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 PROJECT

X1 TCIC STEP4
PROBLEM: tube dent

Brain storm :
1. While taking out condenser core from boxes with one hand.
2. While placing condenser core in trolley.
3. While taking out condenser core from trolley.
4. While placing core on fixture.
5. While bolting with pneumatic gun.
6. While placing assembled condenser core in trolley.
7. May be some fault in the manufacturing process of condenser core.
8. condenser core is sensitive as it has more number of tubes i.e. 49 tubes in
small volume.

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 cause and effect diagram

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 Significance Test – To Check & identify potential significant causes for an effect

Test for Significance :

S. No Probable Cause Significance test Result

Insignificant
1 while taking out verified by visual inspection and found
condenser core with ok
one hand there may
chances of core get
damage by bottom
pad which obstructs
free movement of
core.

Insignificant
2 while placing verified by visual inspection and found
condenser core in ok
trolley there may be
chances of core get
damage by striking
of core with trolley
separators.

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 Significance Test – To Check & identify potential significant causes for an effect

Test for Significance :

S. No Probable Cause Significance test Result

3 while taking out verified by visual inspection. Insignificant

condenser core from
trolley .

4 while placing verified by visual inspection. Insignificant

condenser on fixture

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 Significance Test – To Check & identify potential significant causes for an effect

Test for Significance :

S. No Probable Cause Significance test Result

5 while bolting with verified by visual inspection. Insignificant

pneumatic gun there and found ok because the cap
may chance of core which covers the condenser
get damage due to avoids such incidents.
mishandled operation
with pneumatic gun.

6 while placing verified by visual inspection and Insignificant

assembled core in found ok.
trolley

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 Significance Test – To Check & identify potential significant causes for an effect

Test for Significance :

S. No Probable Cause Significance test Result

7 May be some fault in Unable to verify the Significant

the manufacturing manufacturing process (which is
process of condenser in noida) but we interacted with
core. the people in noida who are
working on the same problem.

condenser core is verified and found not valid as Insignificant

8 sensitive as it has more the same technology of step 4 is
number of tubes i.e. 49 applied to DLE/DLS STEP4 and
tubes in small volume there is no such issues with that
condenser core.

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 conclusion:
after interacting with the people who are working on the same issue in noida
we came to know that there is a problem with oka machine in which a wire
has to adjust to avoid such issues. Moreover before the process of assembly
visual inspection is done by people of condenser line and there itself rejection
of defected core is happening.

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 Case Study

process capability improvement of

tube connectors

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 Case Study : process capability improvement of tube connectors

Team Formation : Mr G.pranay teja ( Team Leader -R&D)

Mr Umesh ( Team Member – SQA)
Mr (Team Member – SCM)
Mr Hruday Ambati ( Facilitator)

Problem Description : In X1, indica and indigo there was a leakage of refrigerant due to fault
groove diameter dimensions of tube connectors.

Start Date :06.01.14

Target Date : 06.03.14

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 DATA COLLECTION

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 HOSE DISCHARGE

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 process capability study
Part name : 646150-7430-0-l USL: 11.78 d2=2.32
Parameter : groove diameter
Specifications: 11.74±0.04 LSL: 11.70
TOLERANCE: 0.08
1 2 3 4 5 6 7 8 9 10

1 11.743 11.748 11.723 11.725 11.732 11.730 11.734 11.733 11.718 11.697

2 11.768 11.754 11.724 11.716 11.719 11.722 11.718 11.696 11.736 11.708

3 11.710 11.694 11.745 11.714 11.709 11.738 11.739 11.699 11.702 11.718

4 11.741 11.718 11.705 11.721 11.738 11.741 11.736 11.731 11.730 11.749

5 11.740 11.695 11.741 11.708 11.734 11.732 11.718 11.739 11.713 11.736

Average 11.7404 11.7218 11.7276 11.7168 11.7264 11.7326 11.729 11.7196 11.7198 11.7216

Range 0.058 0.06 0.04 0.017 0.029 0.019 0.021 0.043 0.034 0.052

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 Xdbar= 11.7256
Rbar=0.0373

S.D.

=0.0373/2.32=0.0161

=0.08/(6*0.0161) =min {0.53,1.126}

=0.828 =0.53

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 Part name : 646150-3730-0-l USL: 11.78 d2=2.32
Parameter : groove diameter
Specifications: 11.74±0.04 LSL: 11.70
TOLERANCE: 0.08
1 2 3 4 5 6 7 8 9 10

1 11.667 11.720 11.718 11.739 11.735 11.709 11.733 11.715 11.745 11.754

2 11.721 11.730 11.718 11.755 11.715 11.738 11.690 11.725 11.740 11.759

3 11.748 11.702 11.720 11.730 11.713 11.745 11.757 11.682 11.741 11.749

4 11.751 11.748 11.705 11.740 11.743 11.733 11.676 11.688 11.676 11.749

5 11.691 11.714 11.729 11.718 11.713 11.710 11.690 11.745 11.770 11.726

Average 11.7156 11.7228 11.718 11.7364 11.7238 11.727 11.7092 11.711 11.7344 11.7474

Range 0.084 0.046 0.024 0.037 0.03 0.036 0.081 0.063 0.094 0.033

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 x dbar=11.7245
R bar=0.0528

S.D.
=0.0227

= 0.5874 =min {0.8149,0.3597}

=0.3597

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 Part name : 646150-4532-0-l
USL: 11.78 d2=2.32
Parameter : groove diameter
Specifications: 11.74±0.04 LSL: 11.70
TOLERANCE: 0.08
1 2 3 4 5 6 7 8 9 10

1 11.744 11.730 11.723 11.741 11.727 11.748 11.740 11.745 11.745 11.737

2 11.748 11.729 11.746 11.755 11.738 11.735 11.733 11.742 11.731 11.723

3 11.712 11.718 11.736 11.741 11.751 11.759 11.745 11.741 11.714 11.724

4 11.734 11.746 11.742 11.746 11.733 11.748 11.742 11.715 11.738 11.841

5 11.736 11.747 11.737 11.745 11.731 11.750 11.743 11.740 11.750 11.733

Average 11.7348 11.734 11.7368 11.7456 11.736 11.748 11.7406 11.7366 11.7356 11.7516

Range 0.036 0.029 0.023 0.014 0.024 0.024 0.012 0.03 0.036 0.118

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 Xdbar=11.7399
Rbar=0.0346

S.D.

=0.0149

=0.8948
=min{0.8926,0.8971}
=0.8926

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 Part name : 646150-1900-0-l
USL: 11.78 d2=2.32
Parameter : groove diameter
Specifications: 11.74±0.04 LSL: 11.70
TOLERANCE: 0.08
1 2 3 4 5 6 7 8 9 10

1 11.750 11.751 11.750 11.756 11.745 11.751 11.742 11.756 11.751 11.746

2 11.770 11.758 11.751 11.767 11.768 11.740 11.738 11.746 11.745 11.734

3 11.738 11.750 11.753 11.747 11.748 11.750 11.743 11.739 11.766 11.740

4 11.759 11.761 11.766 11.746 11.755 11.765 11.745 11.750 11.764 11.740

5 11.740 11.773 11.754 11.751 11.760 11.744 11.745 11.758 11.751 11.745

Average 11.7514 11.7586 11.7548 11.7534 11.552 11.75 11.7426 11.7498 11.7554 11.741

Range 0.032 0.023 0.016 0.021 0.023 0.025 0.007 0.019 0.021 0.012

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 Xdbar=11.7512
R bar=0.0199

S.D.

=0.00858

=min{1.989,1.119}
=1.554 =1.119

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 Part name : 646150-5900-0-l
USL: 11.78 d2=2.32
Parameter : groove diameter
Specifications: 11.74±0.04 LSL: 11.70
TOLERANCE: 0.08
1 2 3 4 5 6 7 8 9 10

1 11.765 11.755 11.761 11.761 11.760 11.766 11.756 11.751 11.754 11.746

2 11.762 11.754 11.765 11.776 11.761 11.765 11.746 11.754 11.747 11.742

3 11.761 11.753 11.761 11.776 11.767 11.760 11.758 11.750 11.769 11.751

4 11.760 11.785 11.755 11.776 11.760 11.760 11.747 11.775 11.762 11.742

5 11.755 11.760 11.763 11.748 11.759 11.750 11.751 11.755 11.751 11.743

Average 11.7606 11.7614 11.761 11.7674 11.7614 11.7602 11.7516 11.757 11.7566 11.7448

Range 0.01 0.032 0.01 0.028 0.008 0.016 0.012 0.025 0.022 0.009

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 Xdbar=11.7582
R bar=0.0172

S.D.

=0.0074

=min{2.622,0.982}
=1.802 = 0.982

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 Part name : 646150-3140-0-l
USL: 11.78 d2=2.32
Parameter : groove diameter
Specifications: 11.74±0.04 LSL: 11.70
TOLERANCE: 0.08
1 2 3 4 5 6 7 8 9 10

1 11.761 11.748 11.755 11.758 11.753 11.756 11.736 11.755 11.737 11.756

2 11.759 11.742 11.740 11.741 11.752 11.744 11.754 11.742 11.748 11.756

3 11.745 11.753 11.758 11.756 11.751 11.753 11.749 11.753 11.753 11.753

4 11.760 11.748 11.737 11.744 11.753 11.759 11.746 11.742 11.747 11.744

5 11.751 11.743 11.757 11.749 11.747 11.741 11.741 11.751 11.755 11.732

Average 11.7552 11.7468 11.7494 11.7496 11.7512 11.7506 11.7452 11.7486 11.748 11.7482

Range 0.016 0.011 0.021 0.017 0.006 0.018 0.018 0.013 0.018 0.024

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 Xdbar=11.7493
Rbar=0.0162

S.D
=0.00698

= min{2.354,1.466}
=1.91 =1.466

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 Conclusion from data
so after analyzing the graphs obtained from cp and cpk of each tube
connector's groove diameter it was found that there are variations in
groove diameters of tube connectors and there is at least 1 part is
defected out of 50 parts of each tube connectors except 3140.

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 Thank You

Suggestions Please …

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