Problem Solving

Using QC story
approach

CUSTOMER COMPLAINTS OF 1109 VECHICLE

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 1.Introduction
CELL :- 1109 AXLE ASSEMBLY
CUSTOMER :- TATA MOTORS LTD. (CVBU-PUNE)
PRODUCT :- REAR AXLE

CVBU : Commercial Vehicle business unit

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 1.1 Problem Definition

LEAKAGE FROM HUB OIL SEAL

Leakage

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 1.2 Effect of Problem

Due to leakage from hub oil seal

1. Lubrication of wheel bearings will be stopped
2. Failure of Braking system
3. Chances of accident

Due to above , it will affect customer satisfaction

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 1.3 Selection of Problem
Plant: Pune TATA MOTORS CVBU DOMESTICS ANALYSIS Model:1109
REPORTING DATE:01.04.08

REAR HUB OIL SEAL LEAKAGE MONTH WISE DATA

10 9

8
6
No.of complaint

6
4
4

0
Sep-07 Oct-07 Nov-07
Month

Total Vehicle production quantity =3266 Nos. (From Sept 07 to Nov 07)
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RSB STARTED AXLE SUPPLY FROM MAY 2007, Warranty Complains
come after 7 to 8 Months of rolling out of Vehicles
 1.4 Process Mapping of HUB ASSY.
Operation 1: REAR HUB WASHING

Operation 2: SPACER TUBE FITMENT

Operation 3: INNER BEARING(2216) PRESSING Grease filled bearing

Operation 4: CIRCLIP FITMENT

Operation 5:OUTER BEARING(2213) PRESSING Grease filled bearing

Operation 6: SPACER FITMENT

Operation 7: OIL SEAL PRESSING

Operation 8: OIL CATCHER PRESSING

Operation 9: HUB BOLT PRESSING

Operation 10: GREES FILLING INSIDE HUB Manual greasing 450

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 1.5 THEME & TARGET

THEME : Eliminate Complaints due to Leakage from Rear Hub oil seal.

TARGET: Zero

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 1.6 TEAM

Facilitator Mr. Sabyasachi Rath

SR.ENGINEER

Leader

Mr. Rajesh Mondal Mr.Bishwjeet Kumar Mr.B.Malik Mr. Harish Patil

Member-Operations Member- Quality Member- Engineering Member- Assembly
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 1.7 How to advance
• GO TO GEMBA.
• Inspect the INPUT materials before assembly.
• Observe HUB assembly & FINAL assembly process.
• Check the tooling , machines & instruments.
• Take immediate containment action.
• Do root cause analysis & take fool proof action.
• Emphasis on finding solutions instead of “who did it”.

10/27/22 Tooling : Dolly & Fixture 9

 2.Gemba Observations

1. All materials received from customer on MASOP basis.

2. 12 ton hydraulic press machine is used for pressing operation .
3. Trained operators are working.
4. Hub & Final assembly process as per SOP.
5. All dolleys & fixtures are calibrated & validated .
6. Visually no oil seal found defective at incoming inspection stage.

10/27/22 Gemba observation done by TEAM date on 05.04.2008 10

 3.Root Cause Identification
3.1.Brain Storming Points
1. Cut mark on lip of oil seal.
2. Pressure ring dimension not ok
3. Alignment of dolly & base plate not ok.
4. Oil seal lip contact not ok.
5. Improper pressing of oil seal.
6. Grease technical parameter not ok.
7. Rear hub dimension not ok.
8. Oil seal dimension not ok.
9. Untrained operators are working.
10. Lack of experience.
11. Excessive greasing in bearing & hub.
12. Blow holes in rear hub.
13. Hydraulic pressure less of press m/c.
14. Frequent breakdown

These are main points found after brainstorming.

( Team including associates did brainstorming.)
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 3.2 Cause & Effect Diagram
Material Method
Material
Cut mark Alignment of dolly
on oil seal Excessive gressing
& base plate not ok in bearing & hub
Blow holes Rear Hub dim. not Improper pressing
in hub ok of oil seal
Grease parameter not ok
Oil seal
dimension Pressure ring dimension not ok
not ok Lip contact not ok of oil seal.
Leakage
Personal
Hydraulic Inadequate from hub
problem Inadequate pressure low measurement oil seal
Training
Lack Old machines
of Experience Poor
Inadequate
Maintenance
Low Frequent instruments
motivation breakdowns

Men Machine
Machine Measurement 12
 3.3 Potential causes listing & validation
S.
NO M'S CAUSE REMARK

BLOW HOLE IN HUB No B/H found in rear hub at incoming inspection

OIL SEAL DIMENSION NOT OK Refer slide No.-17
PRESSURE RING DIM. NOT OK Refer slide No.-16
1 MATERIAL CUT MARK ON OIL SEAL No cut mark found on oil seal found at incoming inspection
LIP CONTACT NOT OK OF OIL SEAL Found OK
HUB DIMENSION NOT OK Refer slide No.-15

GREESE PARAMETER NOT OK After checking at laboratory, parameters found with in specification.
ALIGNMENT OF DOLLEY & BASE PLATE
NOT OK R/O found 0.01MM (Specification=0.02MM)
2 METHOD
IMPROPER PRESSING OF OIL SEAL Pressed hub oil seal parallelism found 0 .014-MM (Spec=0.02MM)
EXESSIVE GRESSING IN HUB & BEARINGS Weight M/C used for hub greasing and m/c used for bearing greasing
PERSONAL PRPBLEM NO PERSONAL PROBLEM
LACK OF EXPERIENCE VERIFY TRAINING RECORD FOUND SUITABLE
3 MEN
INADEQUTE TRAINING VERIFY SKILL MATRIX FOUND SUITABLE
LOW MOTIVATION MOTIVATED
HYRAULIC PRESSURE LOW VERIFY DAILY M/C MAINTAINCE CHECK LIST FOUND OK
POOR MAINTAINCE NO FREQUENT BREAKDOWNS AS PER B.D REPORT
4 MACHINE
OLD MACHINES NEW MACHINES
FREQUENT BREAKDOWNS NO FRQUENT BREAKDOWNS AS PER P.M DONE
INADEQUTE MEASUREMENTS GUAGE R& R CONDUCTED & LESS THAN 10%
5 MEASUREMENT
INADEQUTE INSTRUNMENTS ALL INSTRUNMENTS ARE AVILABLE
13
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 3.4 Cause Validation
1. Collect data for Rear hub.
2. Collect data for Oil seal .
3. Collect data for Pressure ring.

RENSPONSIBLITY– Mr. Bishwjeet Kumar (QA)

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 3.4.1 Cause Validation
RESULT: REAR HUB (Only Major dimension checked) DATE:06.04.2008

S.NO PARAMETER I.D CONCETRICITY

MEASURING
TECHNIQUE USED DIGITAL VERNIER CMM
 
  SPECIFICATION Ø140.0±.2 0.05 All dimensions are
1 140 0.03
with in specification
2 140.06 0.04
3 139.92 0.03
4 139.94 0.03
5 139.96 0.03
6 140.02 0.04
7 140.06 0.04
8 OBSERVATIONS 139.98 0.04
9 139.96 0.03
10 140.02 0.03
11 140.04 0.03
12 139.98 0.03
13 139.96 0.03
14 139.94 0.03
15 139.94 0.04

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All dimensions are in MM.
 3.4.2 Cause Validation
RESULT: PRESSURE RING (Only Major dimension checked) DATE:06.04.2008

S.NO PARAMETER I.D O.D PERPENDICULARITY

MEASURING Digital Digital All parameters are with
CMM
TECHNIQUE USED Vernier Vernier in specification.
  SPECIFICATION Ø86+.035/-0 Ø110-.087/+0 0.02
1 86.02 109.92 .01
2 86.03 109.92 .016
3 86.03 109.93 .018
4 86.01 109.94 .012
5 86.00 109.93 .014
6 86.01 109.92 .012
7 86.03 109.93 .016
8 OBSERVATIONS 86.02 109.93 .012
9 86.02 109.92 .014
10 86.01 109.94 .012
11 86.01 109.94 .01
12 86.03 109.93 .01
13 86.02 109.94 .014
14 86.02 109.92 .016
86.03 109.92 0.012
16
15
10/27/22 All dimensions are in
 3.4.3 Cause Validation
RESULT: OIL SEAL (Only Major dimension checked) DATE:06.04.2008
S. All parameters
NO PARAMETER I.D O.D THICKNESS Lip Contact
are with
MEASURING Digital Digital
Digital Vernier Visual
TECHNIQUE USED Vernier Vernier in specification
No gap between
  SPECIFICATION Ø115.0±.3 Ø139.5±.2 9.5±.2 lip area
1 115.1 139.38 9.3 OK
2 115.18 139.4 9.38 OK
3 115.2 139.32 9.3 OK

4 114.98 139.34 9.32 OK

5 114.96 139.36 9.36 OK
6 114.92 139.4 9.3 OK
7 114.94 139.38 9.32 OK

8 OBSERVATIONS 115.12 139.36 9.3 OK

9 115 139.42 9.36 OK
10 115.12 139.46 9.34 OK
11 115.1 139.46 9.36 OK
12 114.96 139.48 9.38 OK
13 114.98 139.34 9.34 OK
14 114.98 139.38 9.38 OK
15 114.96 139.34 9.36 OK 17
10/27/22 All dimensions are in MM Lip
 3.4.4 Conclusion from data analysis

ALL COMPONENT PARAMETERS FOUND WITHIN

SPECIFICATIONS.
OUR TEAM DECIDED TO REVIEW PREVIOUS DATA &
ANALYSIS.

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 3.4.5 Data collection & analysis

 After review we found that for checking of each parameter

measuring instruments were used but in the case of oil seal no
instruments or guages were used for checking of lip contact area.
 We contacted customer & discussed this observation.
 We jointly developed a Gauge to check Lip Contact of Oil Seal.

We decided to do re-inspection on Date 12/04/2008 for 15 nos 19

 3.4.6 Data collection & analysis
RESULT: OIL SEAL (Only Major dimension checked) DATE:12.04.2008
S. All parameters
NO PARAMETER I.D O.D THICKNESS Lip Contact
are with
MEASURING Digital Digital With the help of
Digital Vernier
TECHNIQUE USED Vernier Vernier gauge in specification
No gap between
  SPECIFICATION Ø115.0±.3 Ø139.5±.2 9.5±.2 lip area
1 115.1 139.38 9.3 OK
2 115.18 139.4 9.38 OK
3 115.2 139.32 9.3 OK

4 114.98 139.34 9.32 OK

5 114.96 139.36 9.36 OK
6 114.92 139.4 9.3 NOT OK
7 114.94 139.38 9.32 OK

8 OBSERVATIONS 115.12 139.36 9.3 OK

9 115 139.42 9.36 OK
10 115.12 139.46 9.34 OK
11 115.1 139.46 9.36 OK
12 114.96 139.48 9.38 NOT OK
13 114.98 139.34 9.34 OK
14 114.98 139.38 9.38 OK
15 114.96 139.34 9.36 OK 20
10/27/22 All dimensions are in MM Lip
 4.WHY WHY ANALYSIS
Leakage from hub oil
seal why

Defective (Lip contact

not ok) oil seal used in why
assembly

Inspection method not why

ok

No Gauge used for lip

contact inspection
21
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 5. Action

Introduced inspection gauge (transparent) for lip contact checking.

Before After

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 5.1 Effect of Action

EFEECT OF ACTION CAN KNOW ONLY AFTER RUNNING OF VECHICLES IN FIELD.

WARRANTY REPORT COMES AFTER SEVEN MONTHS OF ROLLING OUT VECHICLE.

WAITING FOR FIELD COMPLAINTS REPORT

23
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 6.Standardization
AT RSB:
INSPECTION
 Oil seal inspection introduced at incoming inspection stage.

LIST OF INSTRUNMENTS & GUAGES:

 Lip contact checking gauge introduced in instruments & gauges list. (QA/05).

PENDING ACTIONS FOR STANDARIDIZATION:

 During conversion from MASOP to BROUGHT OUT material inspection of lip contact
of oil seal will be introduced in oil seal incoming control plan.

HORIZONTAL DEPLOYMENT:
 For Pinion oil seal, lip contact checking gauge will be made.

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 7.Cummulative Learning

•During process designing , We should take advantages of

customer experience & knowledge.
• During new product development stage, We should keep
attention on previous field failures related to our product &
against this corrective action to be taken at initial stage.
• We should always try to validate our checking systems
through gauges to avoid possible human errors.

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 8. Tools Used.

Cause & Effect

7
Diagram

Check
sheet QC Tools

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 THANK YOU

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