SIX SIGMA

Purpose: To reduce warranty cost of Gasket failures in 4 Cylinder

Engines from Rs.20 Lakhs to Zero.
Project Name : 4 Cylinder Engine Cylinder Head Gasket Failures
Project Focus D M A I C
Selection of project
Vehicle
Stoppage due to
4 Cylinder Engine
Over heating
Fans
Radiator Thermostat
Cylinder Head
Gasket
Coolant Loss/
Leakage
Project Focus
Project Outlook D M A I C
Gasket
failures lead to
Sudden Stoppage of
Engine & Over Heating
Customer Dissatisfaction Cylinder Block
Cylinder Head
G
a
s
k
e
t
Failure Modes D M A I C
What are the Primary Reasons for Gasket Failure
Damaged Gasket
Improper Storage
Bend while Handling
Improper Riveting
Beading Thickness More/Less
Cylinder Head Gasket
Cylinder Head
Surface
finish
Cylinder Block
Flatness
Damages/
Scratches/Dents
Dowel Pin O.D.
Surface
finish
Flatness
Damages/
Scratches/Dents
Dowel hole C.D.
Dowel hole C.D.
Project Overview
Practical Problem
Sudden Stoppage of Engine
due to Overheating
Practical Solution
Statistical Problem
Statistical Solution
10 Red Xs verified and analyzed. 5 found
incapable. Had to dive deeper into Process.
Reduction in failure cost due to Cyl Head
Gasket failure
Results Sustained for more than
12 months & continued
BEFORE
AFTER
Rs.20Lakhs Rs 0.15
Lakhs
CVBU Domestic Warranty Taper Matrix Complaint Analysis as of :
Plant : Pune Model: 709
ENGINAggr : Comp Group : CYLINDER HEAD GASKET BLOWN/LEAKY
Comp Group Cd : AA01039
20-May-09
Dec-08
7
8
6
0
3
7
8
8
2
6
3
9
1
9
3
3
1
4
0
4
3
3
3
4
3
1
4
4
8
8
6
2
8
0
9
1
2
0
5
1
4
0
4
1
6
6
5
9
1
0
8
6
9
4
3
8
9
6
2
9
3
4
2
0
,
5
5
6
1
7
,
3
1
6
1
6
,
8
8
7
1
1
,
9
8
8
6
,
3
1
6
2
,
3
2
8
2
,
3
2
5
2
,
1
5
5
1
,
3
4
4
8
6
2
8
0
9
1
,
2
0
5
1
,
4
0
4
2
,
1
1
1
1
5
8
3
0
5,000
10,000
15,000
20,000
25,000
Dec-
06
Jan-
07
Feb-
07
Mar-
07
Apr-
07
May-
07
Jun-
07
Jul-
07
Aug-
07
Sep-
07
Oct-
07
Nov-
07
Dec-
07
Jan-
08
Feb-
08
Mar-
08
Apr-
08
May-
08
Jun-
08
Jul-
08
Aug-
08
Sep-
08
Oct-
08
Nov-
08
Dec-
08
Last month of 3-monthly prod. batch
c
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m
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v
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03 Mth 06 Mth
12 Mth
Introduction of
MLS Gaskets
CYL.HEAD GASKET FAILURE MODEL 709- 497 ENGINES
CYL.HEAD GASKET FAILURE MODEL 709- 497 ENGINES
AFTER THE INTRODUCTION
OF MLS GASKETS IN MAY07
THERE IS A DRASTIC REDUCTION
IN WARRANTY FAILURES
CVBU Domestic Warranty Taper Matrix Complaint Analysis as of :
Plant : Pune Model: 709
ENGINAggr : Comp Group : CYLINDER HEAD GASKET BLOWN/LEAKY
Comp Group Cd : AA01039
20-May-09
Dec-08
7
8
6
0
3
7
8
8
2
6
3
9
1
9
3
3
1
4
0
4
3
3
3
4
3
1
4
4
8
8
6
2
8
0
9
1
2
0
5
1
4
0
4
1
6
6
5
9
1
0
8
6
9
4
3
8
9
6
2
9
3
4
2
0
,
5
5
6
1
7
,
3
1
6
1
6
,
8
8
7
1
1
,
9
8
8
6
,
3
1
6
2
,
3
2
8
2
,
3
2
5
2
,
1
5
5
1
,
3
4
4
8
6
2
8
0
9
1
,
2
0
5
1
,
4
0
4
2
,
1
1
1
1
5
8
3
0
5,000
10,000
15,000
20,000
25,000
Dec-
06
Jan-
07
Feb-
07
Mar-
07
Apr-
07
May-
07
Jun-
07
Jul-
07
Aug-
07
Sep-
07
Oct-
07
Nov-
07
Dec-
07
Jan-
08
Feb-
08
Mar-
08
Apr-
08
May-
08
Jun-
08
Jul-
08
Aug-
08
Sep-
08
Oct-
08
Nov-
08
Dec-
08
Last month of 3-monthly prod. batch
c
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/

m
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i
o
n

v
e
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c
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03 Mth 06 Mth
12 Mth
Introduction of
MLS Gaskets
CYL.HEAD GASKET FAILURE MODEL 709- 497 ENGINES
CYL.HEAD GASKET FAILURE MODEL 709- 497 ENGINES
AFTER THE INTRODUCTION
OF MLS GASKETS IN MAY07
THERE IS A DRASTIC REDUCTION
IN WARRANTY FAILURES
Scope for Process improvement
48 40 32 24 16 8 0
LSL USL
LSL 0
Target *
USL 50
Sample Mean 38.7188
Sample N 32
StDev(Within) 4.46122
StDev(Overall) 4.38645
Process Data
Cp 1.87
CPL 2.89
CPU 0.84
Cpk 0.84
Pp 1.90
PPL 2.94
PPU 0.86
Ppk 0.86
Cpm *
Overall Capability
Potential (Within) Capability
PPM < LSL 0.00
PPM > USL 0.00
PPM Total 0.00
Observed Performance
PPM < LSL 0.00
PPM > USL 5723.71
PPM Total 5723.71
Exp. Within Performance
PPM < LSL 0.00
PPM > USL 5057.96
PPM Total 5057.96
Exp. Overall Performance
Within
Overall
HD 13 - Flatness
Problem of
Centre & Spread
MLS Gasket
Introduction
D M A I C
PROJECT CTQ Ppk INDEX
Cylinder Head Flatness (Conventional line) 0.86
Cylinder Head Surface finish (Conventional line) 0.77
Makino - Cylinder Head Flatness 0.96
Makino - Cylinder Head Surface finish 1.71
Cyl. Block - Dowel hole C.D. 1.68
Cyl. Head - Dowel hole C.D. 1.72
Dowel pin Diameter - Supplier 1 0.42
Dowel pin Diameter - Supplier 2 1.11
Mounting bolt parameters OK
Material test report - Bolts & Dowel pins OK
Business Case
Aim To reduce failure cost
from Rs.20 Lakhs to Rs. 0
D M A I C
Evaluation of Man,
Machine, Material, Movement
& Method to identify
Red Xs
Xs
Rs.20 Lakhs
Rs. 0
Engine Failures Reduction
Big Y
Big Y
Gasket Failure
Gasket Failure
Sub Y1 - Defective Aggregates
(Cyl Head & Cyl Block)
Sub Y1 - Defective Aggregates
(Cyl Head & Cyl Block)
Xs
Man
Method
Material
Machine
Movement
Flatness, Surface Finish,
Dowel C.D, Damages
Flatness, Surface Finish,
Dowel C.D, Damages
Sub Y2 - Defective Parts from Suppliers
(Dowel Pins, Bolts, Gaskets)
Sub Y2 - Defective Parts from Suppliers
(Dowel Pins, Bolts, Gaskets)
Sub Y3 Parts Movement
(in Trolleys, Rollers)

Sub Y3 Parts Movement
(in Trolleys, Rollers)
Sub Y4 Fixture Condition

Sub Y4 Fixture Condition
Sub Y5 Improving Work men Skill Level
(Process Governance)
Sub Y5 Improving Work men Skill Level
(Process Governance)
OD, Thread Pitch
OD, Thread Pitch
Damages, Scratch,
Dent Marks
Damages, Scratch,
Dent Marks
Pink Xs
Pink Xs
Wear & Tear
Wear & Tear
Poor knowledge
Poor knowledge
Project Charter
Define : 20 Dec 2008
Measure : 15 Jan 2009
Analyze : 13 Feb 2009
Improve : 18 Mar 2009
Control : 02 May 2009
To reduce field failure cost from Rs.20 Lakhs to Rs.0
Project Milestones
Goal Statement
Rest of failed engines are manufactured at
other regions of the country
The failure cost of 4 Cylinder Engines is high due to
gasket failure. Also it contributes towards failure of
other consequential defects in Engine.
Out of Scope
Problem Statement
Of the total failures, 4 Cylinder Engines
constitute 75% failure rate which are
manufactured and assembled in Pune Plant
Customer has field failures such as sudden
stoppage of engine due to over heating. This
mainly happens due to failures in gasket which fits
in between Cylinder Head and Block. The project
intends to eliminate this gasket failures and achieve
customer satisfaction.
In Scope
Business Case
D M A I C
TEAM
Project Scope D M A I C
Manufactured in Other
Regions of the country
Project Scope Eliminate Engine failure cost of
Types 4 Cylinder which contributes almost 75%
of overall failure cost manufactured in Pune Plant
38%
62%
4 Cylinder
Engine Type 1
4 Cylinder
Engine Type 2
6 Cylinder
Engine Type 3
6 Cylinder
Engine Type 4
6 Cylinder
Engine Type 5
36%
39%
25%
75%
SIPOC Diagram D M A I C
SUPPLIER
INPUT INPUT
SUPPLIER
PROCESS
Supplier 1
Supplier 2
Dowel Pin
Production
Line No. 2 & 8
Dowel Pin Insertion
into Cylinder Block
Cylinder
Block
Supplier 3
Place Gasket on
Cylinder Block
using Locating Pin
Gasket
Production
Line No.5
Cylinder
Head
Place Cylinder Head on Block
by resting it on Gasket
Supplier 4
Insert and tighten
the Bolts
Mounting
Bolts
CYLINDER HEAD
GASKET ASSEMBLY
OUTPUT
CUSTOMER
Engine Section &
End User
Consequential Failures
D M A I C
CONSEQUENTIAL FAILURES DUE TO GASKET FAILURE IN 4 CYLINDER ENGINES
HEOC
20%
Conrod
Failures
51%
Hydrostatic lock
1%
Oil leak
2%
Piston ring
seizure 9%
Water in
oil 2%
Gasket
Blown 2%
Head Def
3%
Cyl Bore
worn 7%
Over heat
3%
Measurement System Analysis
D M A I C
D M A I C
Process capability Analysis
Cylinder Head Conventional line S/finish
48 40 32 24 16 8 0
LSL USL
LSL 0
Target *
USL 50
Sample Mean 38.7188
Sample N 32
StDev(Within) 4.46122
StDev(Overall) 4.38645
Process Data
Cp 1.87
CPL 2.89
CPU 0.84
Cpk 0.84
Pp 1.90
PPL 2.94
PPU 0.86
Ppk 0.86
Cpm *
Overall Capability
Potential (Within) Capability
PPM < LSL 0.00
PPM > USL 0.00
PPM Total 0.00
Observed Performance
PPM < LSL 0.00
PPM > USL 5723.71
PPM Total 5723.71
Exp. Within Performance
PPM < LSL 0.00
PPM > USL 5057.96
PPM Total 5057.96
Exp. Overall Performance
Within
Overall
HD 13 - Flatness
Ppk=0.86
Cylinder Head Conventional line Flatness
Ppk=0.77
Cylinder Head Makino line Flatness
Cylinder Head Makino line S/Finish
Ppk=1.71
Ppk=0.96
Cylinder Block Centre Distance
1
3
.
9
9
8
1
3
.
9
9
2
1
3
.
9
8
6
1
3
.
9
8
0
1
3
.
9
7
4
1
3
.
9
6
8
1
3
.
9
6
2
LSL USL
LSL 13.957
Target *
USL 14
Sample Mean 13.9845
Sample N 32
StDev(Within) 0.00448897
StDev(Overall) 0.00464192
Process Data
Cp 1.60
CPL 2.04
CPU 1.15
Cpk 1.15
Pp 1.54
PPL 1.98
PPU 1.11
Ppk 1.11
Overall Capability
Potential (Within) Capability
PPM < LSL 0.00
PPM > USL 0.00
PPM Total 0.00
Observed Performance
PPM < LSL 0.00
PPM > USL 284.53
PPM Total 284.53
Exp. Within Performance
PPM < LSL 0.00
PPM > USL 430.49
PPM Total 430.49
Exp. Overall Performance
Within
Overall
Process Capability of Sahyadri
Dowel Pin Diameter Supplier 2
D M A I C
Ppk=1.68
Ppk=1.11
Cylinder Head Centre Distance
Ppk=1.72
14.008 14.000 13.992 13.984 13.976 13.968 13.960
LSL USL
LSL 13.957
Target *
USL 14
Sample Mean 13.9931
Sample N 32
StDev(Within) 0.00634836
StDev(Overall) 0.00549927
Process Data
Cp 1.13
CPL 1.90
CPU 0.36
Cpk 0.36
Pp 1.30
PPL 2.19
PPU 0.42
Ppk 0.42
Overall Capability
Potential (Within) Capability
PPM < LSL 0.00
PPM > USL 0.00
PPM Total 0.00
Observed Performance
PPM < LSL 0.01
PPM > USL 139413.74
PPM Total 139413.75
Exp. Within Performance
PPM < LSL 0.00
PPM > USL 105619.34
PPM Total 105619.34
Exp. Overall Performance
Within
Overall
Process Capability of Ganesh Auto
Dowel Pin Diameter Supplier 1
Ppk=0.42
Process capability Analysis
D M A I C
Metrology Report Bolts Metallurgy Report - Bolts
Metrology & Metallurgy check
Metallurgy Report Dowel Pins Supplier 1
Metallurgy Report Dowel Pins Supplier 2
Metrology & Metallurgy check
D M A I C
Summary
D M A I C
PROJECT CTQ Ppk INDEX
Cylinder Head Flatness (Conventional line)
0.86
Cylinder Head Surface finish (Conventional line)
0.77
Makino - Cylinder Head Flatness
0.96
Makino - Cylinder Head Surface finish
1.71
Cyl. Block - Dowel hole C.D.
1.68
Cyl. Head - Dowel hole C.D.
1.72
Dowel pin Diameter - Supplier 1
0.42
Dowel pin Diameter - Supplier 2
1.11
Mounting bolt parameters
OK
Material test report - Bolts & Dowel pins
OK
Identification of Causes
D M A I C
Gasket
Failure
MAN
MACHINE
METHOD
Less torque
Excess torque
Tightening Socket
worn
Defective
Cylinder Block*
Unclean mating surfaces
Poor Application of oil on
Bolt threads
Untrained operator
Defective Dowel Pins*
Not following 100% Hand
Torque after M/c torque
Wrong sequence of Hand torque when M/c
Under B/Down
Defective
Head Bolt*
Input
Defective Gasket*
Cylinder Liner sinking
Damaged Dolly
Poor sorting of
Used/unused Gaskets
in Rectification
Using Wrong Alignment pin
Defective Cylinder Head*
Surface Finish not ok
Flatness not Ok
CD of Dowel
Hole out
Dent Mark on
Mating Surfaces
Surface Finish not ok
Flatness not Ok
CD of Dowel
Hole out
Dent Mark on
Mating Surfaces
Diameter
Length
Hex. Size
Strength of Bolt
Excess/Short Length
Thread
Damage
Beeding
Thickness
Cullet
Condition
Riveting
not ok
Bend while
storage
Chamfer
Beed condition
2
4
3
1
1
4
3
1
4
2
3
4
4
4
3
3
3
1
1
3
3
3
3
4
4
1
2
2
1
2
1 2
3 4
I
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t
Easy
Hard
Impact
High Low
1
1
MATERIAL
4 Cylinder
Engines
Effect of Causes
D M A I C
Potential Failure Mode and Effect Analysis
Face Flatness
exceeds
(0.05 mm Max),
Leakages
through
Cylinder Head
Gasket.
6
Distortion of
Component due to
Clamping, Tool
wear,Wrong Cutter
Setting,Play more in
M/c Spindle,Improper
Camber Angle of
Cutter
3
1)Tool Life Monitoring Checklist
2) Air Cleaning of Pads
First Piece
Check &
Periodic
Inspection
6
108
Surface finish
exceeds
15m Rz
Leakages
through
Cylinder Head
Gasket.
6
Improper Component
Seating, Cutter Tips
Wear out
3
1)Tool Life Monitoring 2) Air Cleaning
of Pads after every Cycle Completion
First Piece
Check &
Periodic
Inspection
6 108
Dent marks on
Head Face
Leakages
through
Cylinder Head
Gasket.
7
Improper Handling of
Jobs while
transporting (Internal
and External)
3
1)Tool Life Monitoring 2) Air Cleaning
of Pads after every Cycle Completion
Periodic
Inspection
6 126
Current Process Controls
Prevention
Potential
Failure Mode
Potential
Effect(s) of
Failure
Sev
Process
function

Requirement
Potential cause(s) /
Mechanism(s) of
Failure
C
l
a
s
s
Current
Process
Controls
Detection
Dete
ction
RPN Occ
Head Face
Finish Milling
Sev (Severity) x Occ (Occurrence) x Det (Detection) = RPN (Risk Priority Number)
Process Capability Analysis
D M A I C
Process is less capable and spread is more. Also process is
decentralized and it is shifted more at higher side..
Flatness of Cylinder Head
Process Capability Analysis
D M A I C
Surface Finish of Cylinder Head
Process is less capable and spread is more. Also process is
decentralized and it is shifted more at higher side..
MATERIAL
METHOD
Untrained Operator
Camber Angle Improper
No Cutter Life
Monitoring
Varied
Speed & Feed
Improper Resting
on Pads
Faulty
Drive
Slide Lub ineffective
MACHINE
Valve Guide Pressing
Distortion High
Wrong
Cutter Setting*
Cutter Setting Face Run out More
Improper Mounting of Cutter to Spindle
*
Improper Material
Hardness
Flatness &
Surface Finish
Fish Bone Diagram
1 2
3 4
I
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t
Easy
Hard
Impact
High Low
1
3
3
1
MAN
1
2
2
D M A I C
1
3
1
Improvements (ECRS technique)
D M A I C
+1
x
1.5x
POKA YOKE for Cutter Life Monitoring
+1.5
DIAL
SETTER
Shim of
0.05mm
Bottom Face of Cutter
Free from Dent marks
Use of Fixed Pocket Cutters
Ensuring Cutter Mounting to
Spindle Arbor
JOB
Air
sensing
Pads
POKA YOKE for Job Seating
1
2
3
Machine stops Automatically after the
count reaches 50
4 Cylinder
6 Cylinder
2E
4E 3R
0.025
250 FACE
MILLING
CUTTER
Camber Angle
Adjustment
5S
1C
Face Flatness
exceeds (0.05
mm Max),
Leakages
through Cylinder
Head Gasket.
6
Distortion of
Component due to
Clamping, Tool
wear,Wrong Cutter
Setting,Play more in
M/c Spindle,Improper
Camber Angle of Cutter
1
1)Tool Life Monitoring-POKAYOKE 2)
Air Cleaning of Pads after every Cycle
Completion-POKAYOKE
3) Cutter Setting improved.
4) Usage of newer Inserts and wipers
First Piece
Check &
Periodic
Inspection
6
36
Surface finish
exceeds 15m
Rz
Leakages
through Cylinder
Head Gasket.
6
Improper Component
Seating, Cutter Tips
Wear out
1
1)Tool Life Monitoring-POKAYOKE 2)
Air Cleaning of Pads after every Cycle
Completion-POKAYOKE
3) Cutter Setting improved.
4) Usage of newer Inserts and wipers
First Piece
Check &
Periodic
Inspection
6
36
Dent marks on
Head Face
Leakages
through Cylinder
Head Gasket.
7
Improper Handling of
Jobs while transporting
(Internal and External)
1
1) Trolley Design Modified
2) Rollers are given a relief at the Middle
Portion
Periodic
Inspection
6
42
Current Process Controls
Prevention
Process
function

Requirement
Potential Failure
Mode
Potential
Effect(s) of
Failure
Sev
Head Face Finish
Milling
Current
Process
Controls
Detection
Dete
ction
RPN
C
l
a
s
s
Potential cause(s) /
Mechanism(s) of
Failure
Occ
Effect of Improvement Actions
Potential Failure Mode and Effect Analysis
Sev (Severity) x Occ (Occurrence) x Det (Detection) = RPN (Risk Priority Number)
D M A I C
Effect of Improvement Actions
D M A I C
Flatness of Cylinder Head
Process capability is OK. Process is centralized. Also the spread is reduced.
BEFORE ACTION AFTER
Work Supports changed to Fixed Pads
Cutter with
Thru Coolant
Arrangement
Sub Y1 :Defective Aggregates Flatness & Surface Finish of CNC Line
Before
After
Milling Path Straight
Milling Path Angular
D M A I C
1R
2R
3C
Improvements (ECRS technique)
14.008 14.000 13.992 13.984 13.976 13.968 13.960
LSL USL
LSL 13.957
Target *
USL 14
SampleMean 13.9931
SampleN 32
StDev(Within) 0.00634836
StDev(Overall) 0.00549927
ProcessData
Cp 1.13
CPL 1.90
CPU 0.36
Cpk 0.36
Pp 1.30
PPL 2.19
PPU 0.42
Ppk 0.42
Overall Capability
Potential (Within)Capability
PPM<LSL 0.00
PPM>USL 0.00
PPMTotal 0.00
ObservedPerformance
PPM<LSL 0.01
PPM>USL 139413.74
PPMTotal 139413.75
Exp. WithinPerformance
PPM<LSL 0.00
PPM>USL 105619.34
PPMTotal 105619.34
Exp. Overall Performance
Within
Overall
Process Capability of GaneshAuto
1
3
.
9
9
8
1
3
.
9
9
2
1
3
.
9
8
6
1
3
.
9
8
0
1
3
.
9
7
4
1
3
.
9
6
8
1
3
.
9
6
2
LSL USL
LSL 13.957
Target *
USL 14
SampleMean 13.9845
SampleN 32
StDev(Within) 0.00448897
StDev(Overall) 0.00464192
ProcessData
Cp 1.60
CPL 2.04
CPU 1.15
Cpk 1.15
Pp 1.54
PPL 1.98
PPU 1.11
Ppk 1.11
Overall Capability
Potential (Within)Capability
PPM<LSL 0.00
PPM>USL 0.00
PPMTotal 0.00
ObservedPerformance
PPM<LSL 0.00
PPM>USL 284.53
PPMTotal 284.53
Exp. WithinPerformance
PPM<LSL 0.00
PPM>USL 430.49
PPMTotal 430.49
Exp. Overall Performance
Within
Overall
Process Capability of Sahyadri
14
17
1 x 45
Process
capability
should be
>1.67
BEFORE ACTION AFTER
Supplier 1
Supplier 1
Supplier 2
Supplier 2
Sub Y2 : Defective Parts from Supplier - Process Correction
Dowel Pin
Dimension control
-43
Awareness to Suppliers
Control
on
Incoming
Gaskets
2
1
3
D M A I C
Improvements (ECRS technique)
Improvements (ECRS technique)
D M A I C
Sub Y3 : Parts Movement (Internal/External)
Chips on Rollers
Rollers are given a relief in the Middle Portion
( Cylinder Head Gasket Area is Protected)
JOB
Internal Improvements
External Improvements
Use of Protective Stickers on Milling Surface
Teflon Blocks on Trolley to
prevent Milling Surface
Damages
Hanging Trolley made
Head Face free from
Damages
EFFECT
1R
2R
3R
4R
OK
Next
Operation
Check
Drive
OK
Not OK
Next Operation
Apply Torque
Check Torque
Value
Check Socket
Condition
Replace
Inspect First
Job
Not OK
OK
Worn out
Sockets
Preventive
Maintenance
of
Sockets
Change
Sockets
after 10000
Cycles
Not OK
Record & Reset
Sub Y4 :Fixture Condition
BEFORE AFTER
D M A I C
CYL HEAD
CYL BLOCK
DOWEL PINS
Dolly

Pressing Force
Process Flow for Dollys fixed and both the items are added in Audit Check Points
1
2
Improvements (ECRS technique)
Improvements (ECRS technique)
D M A I C
Sub Y5 : Improving workmen skills and Preventing Human Errors
Damaged Gaskets
Bin
IN
5S - Damaged Gaskets
usage avoidance
ON THE JOB TRAINNG
ENHANCEMENT IN WORKMEN SKILLS
Automatic Bolt oiling linked to
Conveyor movement
AVOIDING HUMAN ERRORS
1
2
3
4
6
5
Project Results
D M A I C
Rs.20 Lakhs
Rs 0.15
Lakhs
Reduction in Field Failure Cost
Improvement in Sigma Level
90% Reduction in
Consequential failures
Process
Improvements
D M A I C
Positrol
Tools & Techniques used
D M A I C
List of Tools & Techniques
List of Pokayokes
1) Cutter Life Monitoring in Milling M/c
2) Air Sensing in Milling M/c
3) Fixed Pocket Cutter in Place of
Movable Cutters
4) Thru Spindle Coolant arrangement
in Makino Milling M/cs
5) Fixed Pads in Case of Movable
work Supports
6) Engine Assy Socket Replacement
7) Automatic Bolt oiling linked to
Conveyor Movement
1) Cause & Effect
Diagram
2) PFMEA
3) Process Capability
4) Process Flow Diagram
5) ECRS Techniques
6) TGRs & TGWs
7) Bench Marking
8) 5S & X Bar-R Chart
All Documents like PFMEA,Control Plan,Quality Alerts are suitably updated as
per Process Changes
Deployment of Learning's
D M A I C
Air sensing for Job Seating
Tool Monitoring
Cutter change made easy by
. Flexible Arm arrangement
Usage of Fixed Pocket Cutters
Provision of Dial stand for Easy
Cutter Adjustments
Reconditioned Machine
Cylinder Head Block Contact Face Milling
Machine
Implementation of actions made applicable to 6 Cylinder Engine.
Project details shared with Tata Motors, Jamshedpur Plant for horizontal
deployment of actions initiated at Pune Plant.
Effectiveness Monitoring
0.5/1000
0.1/1000
0.1/1000
0.1/1000
0.90/1000
4/1000
0.90/1000
0.6/1000
Before
After
Before
After
Before
After
Before
After
Thank You