QC STORY

CB - N3 Concern Reduction
(Major - Cylinder Block Face 101& 301
Perpendicularity NG)

PWT | 27 Mar 2017

 QC story
Methodology 8.Conclusion,Review & Future Actions

7.Standardization

6.Result Checking

5.Implementation of Countermeasures

4.Determination of Countermeasures

3.Factor Analysis

2.Grasping Current Condition & Target Setting

1.Theme selection

PWT | 27 Mar 2017

  1.1.THEME SELECTION

CYL Block Perpendicularity NG Occurrence Status

4
F301/101 Continous rejection

There’s Continuous Rej

3
No Of Occurrence

3
Due to F301/101 Perp NG

2
2 2
Actual
Target

1
1

0
Jan-17 Feb-17 Month
Mar-17 Apr-17

PWT | 27 Mar 2017

2.Grasping Current Condition

3C -N3 Concern Trend Block -N3 Concern Trend

60 25
49 21
50 20 19
40
15
30
20 10
20 7 6
14 5 5
11
10 8 5
5 3 4 2 1
0 0
Jan-17 Feb-17 Mar-17 Apr-17 May-17 Jun-17 Jul-17 Aug-17 Jan-17 Feb-17 Mar-17 Apr-17 May-17 Jun-17 Jul-17 Aug-17

Block - Major concern Pareto

20 100% 100%
95%
18 90%
16 80%
75%
14
65%
12
10 8 50%
8 40%
6 5
3 25%
4 2
2 1 1
0 0%
301 Perp NG 5001 Perp NG Main Bore 1022 and 1012 3012,3013,3014 101 Perp NG
Roughness - NG Hole Position NG hole position NG

PWT | 27 Mar 2017

 Details of Face 101& 301 Perpendicularity
301 Front Cover
Mounting
F101 Gear Box
Mounting

 Face 101 & 301 Perpendicularity WRT D-E(Crank Bore) NG

 ┴ Spec 0.08mm actual 0.09 & 0.1mm

Crank Bore –Boring at OP80 Face Milling 301- OP90 Face Milling 101- OP90
PWT | 27 Mar 2017
2.1 Target Setting

No of Leak Defect
40%

5%

0
F301 NG Target

PWT | 27 Mar 2017

3. ANALYSIS: CAUSE & EFFECT DIAGRAM

MAN Shift to Shift MACHINE

correction Wear Parts checked
Base Mounting
Condition checked KM0 Condition
Position Vibration
correction checked X,Y,Z&B axis Checked
Used Insert
Mounted Improper
Miss Correction in Over Loaded
Judgement of Program Butting Plate Loading Pin
insert

Perpendicularity NG
Gap Found
Tool Locating Pin Butting Not
setting Part Butting good
Part butting is
With Runout tool not Available
setting Done Part and
Butting Gap
10 Probable causes are identified
Insert Blend
Tool Run out More

Tool Condition Visual check Insert Life

is Less
Insert Hit in
the Guide Pressing condition Not
Tool
able to check Insert Life
Over
Tool Guide Tool Loading not
Hang
Design NG Method achieved

METHOD MATERIAL

PWT | 27 Mar 2017 Probable causes are identified through 4M method

Genba Validation result
Category Area Main Factors Validation Result

OP80 Used Insert Mounted Insignificant -- O

OP80 With Runout tool setting Done Insignificant -- O

MAN
OP80 Shift to Shift correction Insignificant -- O

OP80 Improper Correction in Program Insignificant -- O

X,Y,Z&B axis Checked Variation Significant - X

MACHINE OP80
Locating Pin Butting Not good Insignificant -- O

OP80 Tool Run out More Insignificant -- O

METHOD
OP80 Tool Guide Design NG Insignificant -- O

OP80 Insert Blend Insignificant -- O

MATERIAL
OP80 Tool Life not achieved Significant - X

PWT | 27 Mar 2017

 SIGNIFICANT

PWT | 27 Mar 2017

 SIGNIFICANT

IMPLEMENT SOLUTIONS-(Top-3) TOOL LIFE VALIDATION

Tool (1) Life – 500 Nos Tool (2) Life – 525 Nos

1.Crank bore Perpendicularity has been

measured in CMM for each 50nos/once

2.Based on the Measurement

perpendicularity found out off limit when the
tool life is more than 500nos.

Tool (3) Life – 500 Nos Tool (4) Life – 500 Nos

PWT | 27 Mar 2017

5 . Implementation of Countermeasures

Sl. What (Activity) Why Who When Where How Status

No.

Tool Life revised from

1 Tool life not achieved Tool Maint WK12 Trial and validation Completed
750 nos to 500Nos

OP80

B-Axis angle adjusted B to C=200µ observed Table repeatability found-0.00

2 Mfg WK17 Completed
+30 °in the Program against ± 0.03 Rest Pad Changed.

PWT | 27 Mar 2017

 IMPLEMENT SOLUTIONS
Maximum tolerance
Fixture side KM0:
Before AFTER
C 200µ B 10µ C 15µ B 10µ

Tolerance ±30µ Tolerance ±30µ

D 18µ A 0µ D 18µ A 0µ

 B-Axis at 0˚  B-Axis at 0˚
 A=0  A=0
 A to B=10µ  A to B=10µ
 B to C=200µ  B to C=15µ
 C to D=18µ  C to D=18µ
 Table repeatability found-0.00
 Rest Pad Changed.

PWT | 27 Mar 2017

 IMPLEMENT SOLUTIONS-(Top-1)
B- Axis Angle adjusted to +30̊ Crank Bore Measurement

Axis Direction
CYL Block Front Side

Tool Direction

Machine
CYL Block Exhaust Tool
Side
Spindle

Fixture

B-Axis Direction adjusted to +30 ̊

To bring the crank bore -1 and 3 to inline

( Taper 0.04 mm)

PWT | 27 Mar 2017

 IMPLEMENT SOLUTIONS-(Top-1)

Job View In loading condition

B- Axis Angle adjusted in Program

PWT | 27 Mar 2017

 IMPLEMENT SOLUTIONS-(Top-3) TOOL LIFE VALIDATION
BEFORE (TOOL LIFE -750 Nos) AFTER (TOOL LIFE -500 Nos)

Tool life limit changed from 750 nos to 500 nos

PWT | 27 Mar 2017

 STANDARDIZATION(Top-1)

Item`` What Why Who When Where How STATU

S

Standardization B-Axis angle

To bring Crank Bore Cylinder adjusted +30
B-Axis angle MAINT 24-3-2017
1 and 3 inline Block –OP80 °in the
Program

Job View In loading

condition

B- Axis Angle adjusted in Program

PWT | 27 Mar 2017

 STANDARDIZATION(Top-3)

Item What Why Who When Where How STATU

S

Tool Life
Standardization To avoid revised
Tool Cylinder
Tool life Perpendicularity 03-4-17 from 750
MAINT Block –P80
NG nos to
500Nos

BEFORE AFTER

PWT | 27 Mar 2017

 STEP-5 SUSTAIN AND EVALUATE- CHECK POINT ADDED IN POS

Check Point added in Process

Operation Sheet and
Perpendicularity ( Face 101)
monitored in N1 Parameter

Face Milling 101- OP90

PWT | 27 Mar 2017

 STEP-5 SUSTAIN AND EVALUATE - CHECK POINT ADDED IN POS

Check Point added in Process

Operation Sheet and
Perpendicularity ( Face 301)
monitored in N1 Parameter

Face Milling 301- OP90

PWT | 27 Mar 2017

 STEP-5 SUSTAIN AND EVALUATE – N1 MONITORING
Cylinder block line Layout

OP 80&80A
Crank Bore
Machining

Perpendicularity Parameter
added in N1 Monitoring

PWT | 27 Mar 2017

STEP-5 (SUSTAIN AND EVALUATE)- NO OF OCCURRENCE
CYL Block Perpendicularity NG Occurrence Status
4
1st metric Target Achieved

3
3 Last 3 weeks there is no
perpendicularity NG
No Of Occurrence

2 2 After Tool Life Revision

2
Actual
Target

1
1

0 0 0 0
0
Jan-17 Feb-17 Mar-17 Apr-17 May-17 Jun-17 Jul-17 Aug-17
Month
PWT | 27 Mar 2017