A Project Report on

“Defect Reduction In Qsk

23 Camshaft Model Using
Zero Defect Tool”

Submitted By
Hrishikesh Shankar Bidgar
Aryan Felix Fernandes
Under The Guidance
Prof. Ashish Gandigude.

Department of Mechanical Engineering

Zeal Education Society’s

Zeal College of Engineering and Research

[2022-2023]
Narhe, Pune - 411041
 Zeal Education Society’s

Zeal College of Engineering and Research,

Narhe, Pune - 411041

CERTIFICATE
This is to certify that Mr. Aryan Felix Fernandes, has successfully
completed the Project Stage – I entitled “Defect Reduction In Qsk 23
Camshaft Model Using Zero Defect Tool” under my supervision, in
the partial fulfillment of Bachelor of Engineering - Mechanical Engineering
of University of Pune.

Date: / /
Place:

Prof. Ashish Gandigude

Project Guide Internal Examiner

Prof. S. M. Godase Dr. Ajit M. Kate

Head of Department Principal

External Examiner
 Zeal Education Society’s

Zeal College of Engineering and Research,

Narhe, Pune - 411041

CERTIFICATE
This is to certify that Mr. Hrishikesh Shankar Bidgar , has
successfully completed the Project Stage – I entitled “Defect Reduction
In Qsk 23 Camshaft Model Using Zero Defect Tool” under my
supervision, in the partial fulfillment of Bachelor of Engineering -
Mechanical Engineering of University of Pune.

Date: / /
Place:

Prof. Ashish Gandigude

Project Guide Internal Examiner

Prof. S. M. Godase Dr. Ajit M. Kate

Head of Department Principal

External Examiner
 ACKNOWLEDGMENT

I take this opportunity to express my sincere gratitude towards the Department of Mechanical
Engineering, ZCOER, PUNE that gave me an opportunity for presentation of my Project Stage-
I in their esteemed organization.

I would like to express my sincere thanks to my Project guide Prof. Ashish Gandigude
and Head of the Department Prof. S. M. Godase without whose guidance and adequate
facilities. I would not have completed my Project Stage-I, his valuable advice made it easy for
me to proceed for this Project Stage-I.

I express my sincere thanks to Project Coordinator Prof A. V. Karande for his constant support
and experienced guidance and providing me precious help and advice without which the
successful completion of this Project Stage I would not have been possible. I am also thankful
to Dr A. M. Kate Principal, ZCOER, PUNE for giving me necessary resources and support to
complete my Project Stage-I.
I would like to express my sincere thanks to Cummins India Ltd. For allotting us the
sponsored project and supporting us in our project.

Last but not the least, I thank all others, and especially my classmates and my family members
who in one way or another helped me in the successful completion of this work.

Mr. HRISHIKESH S. BIDGAR

Mr. ARYAN F. FERNANDES

I
 CONTENTS

Sr. Description Page.

No. No.

1 Introduction
1
1.1 Problem Statement
2 Problem Statement
4
2.1 Objectives

2.2 Methodology

3 Literature Review
6
3.1 Literature Summery

4 Data Collection 11

5 Quality Control Techniques 21

5.1 Selection Of Most Suitable Defect Reduction Technique 29

6 Machine Selection 30

7 Implementation On Tempering Furnance

32
7.1 Poka-Yoke Applied

8 Implemention Of Pokayke On Various Machines 34

9 Conclusion 36

10 Referance 38

II
 LIST OF FIGURES

Figure No. Name of Figure Page No.

2.1 methodology 5

4.1 Flow chart 11

4.2 Keyway milling 12

4.3 Induction hardening 13

4.4 Tempering machine 14

4.5 Shot blasting 15

4.6 Cam straightening 15

4.7 Cam grinding 16

4.8 Crack test 17

4.9 Data of cam rejection from 2018 18

4.10 Camshaft rejection action plan 19

5.1 Six sigma 20

5.2 Pareto chart 23

5.3 Poka-yoke techniques. 25

6.1 Pareto chart 28

6.2 Tempering furnace 29

7.1 Previous layout 30

7.2 Modified layout 32

8.1 Currently working poka-yoke 33

9.1 Pareto chart after defect reduction 35

III
 LIST OF TABLE

Figure No. Name of Figure Page No.

6.1 Defect chart 29

8.1 Machine selction 34

9.1 Implementaion of poka-yoke 37

IV
 “Defect Reduction In Qsk 23 Camshaft Model Using Zero Defect Tool”

ABSTRACT

The efficiency of an IC engine is mainly depending on opening and closing of inlet

and outlet valves. The valves are operated by cam shaft. So cam shaft must be free
from defects to maintain proper combustion of an internal combustion engine. Thus,
we focused on reducing the defects and improving quality in the manufacturing
process and operations of a camshaft in manufacturing industry for different
automotive. In camshaft manufacturing the considerable defects are material selection,
changing of their mechanical properties while machining, temperature defects, casting
defects, tolerances and surface roughness. So manufactured cam shaft has to
overcome above defects for safe operating of valves. We studied various quality
control tools and implement it to reduce the defect.

Keywords: camshaft, defects, quality control tools.

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Chapter 1

1.1 INTRODUCTION

A camshaft is a shaft that contains a row of pointed cams, in order to

convert rotational motion to reciprocating motion. Camshafts are used in piston
engines (to operate the intake and exhaust valves), mechanically controlled ignition
systems and early electric motor speed controllers.

Camshafts are made from metal and are usually solid, although hollow camshafts are
sometimes used The materials used for a camshaft are usually either:

 Cast iron: Commonly used in high volume production, chilled iron camshafts
have good wear resistance since the chilling process hardens them.
 Billet steel: For high-performance engines or camshafts produced in small
quantities, steel billet is sometimes used. This is a much more time-consuming
process, and is generally more expensive than other methods.

Fig 1.1
Lobes: as the spins, the lobes rotate together with the piston motion. The functions of
the lobes are to open and close the valve for the intake and exhaust gases. The speed
of the cam lobes depends on the engines speeds.

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Ends: the front end of the cam is designed to carry belt to connects with the
crankshaft. The rear end of the cam turns the distributor of the engine with a special
gear. The ignition timing in tune with the rest of the engine with this part.

Bearings: is a mounted in conjunction with the main journals. It helps to prevent the
camshaft from damaging the engine block when the engine becomes faulty. Bearings
help to keep the rotation of camshaft seamless.

“A defect in manufacturing is one that the manufacturer did not intend” It defines a
manufacturing defect as occurring when "the product departs from its intended design
even though all possible care was exercised in the preparation and marketing of the
product."

A defect in manufacturing camshaft leads to rejection of camshaft from vendor,

hence leading to loss of time, money and labour, therefore reduction of defect
pays a crucial part in increasing the efficiency of the industry.

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Chapter 2

2.1 PROBLEM STATEMENT

Camshaft is a crucial part of internal combustion engine for determining opening
and closing valve timing defect in camshaft may lead to reduced engine
performance due to cylinder misfire. A defect in QSK 23 camshaft may lead to
increase production cost, impair product quality, reduce engine lifespan, impact
customer satisfaction and result in colossal waste of resources which may
adversely affect the manufacturer by reducing the manufacturing efficiency and
also affect the consumer relationship which reduces profit.

2.2 OBJECTIVES

 Study various camshaft manufacturing processes and introduce various

automation ideas for the betterment of processes.

 To study various quality improvement tools and data collection of the

defects.

 To work in order to reduce the defect in camshaft manufacturing process

by implementation of quality tools.

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2.3 METHODOLOGY:

Fig 2.1 methodology

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Chapter 3

3.1 LITERATURE SURVEY:

3.1.1] Reducing Defects on Cam Shaft by Six Sigma Methodology

Md. K. M. Farooqui et al., The application of Six Sigma, a corporate strategy and
methodical methodology, leads to success through a quantum improvement in product
quality, customer loyalty, and efficiency. The objective was to reduce the number of
abnormalities to 3.4 parts per million chances. Methodology: DMAIC is one of the six
sigma tools used to enhance processes and also to identify the root causes of any
issues in order to lower defects that occur in any company. To cut down on errors and
raise the quality, we are employing the DMAIC tool. Define, measure, analyse,
improve, and control is referred to as DMAIC

3.1.2] Failure Analysis of Camshaft - A Review

Shweta Ghodke et al., The paper reviews engine camshaft static, structural still as
model analysis. The Camshaft is nothing more than an important component found in
the engines of cars and other applications. The camshaft is crucial to the efficient and
smooth operation of engines. The project's objective is to model and analyses the
camshaft using FEM. Today's top camshaft producers have created a variety of cam
profile designs with the aim of achieving a positive and effective engine performance.
Analysis of engine component failure under simultaneous loading is essential since
engine running involves Numerous studies have been published to far on the failure of
engine components. Various pieces of software are used to accomplish the research,
with ANSYS possibly being the most well-liked in the present day. The camshaft is
continuously subjected to high speed rotational movement, which causes vibrations in
the system. It is a mechanism used to operate engine valves with proper
opening/closing timings. The contact between the plunger and the cam exposes them
to different contact fatigue stresses as well. These

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3.1.3] A Holistic Approach to Zero Defect Castings

B. Ravi et al., Casting rejections – as high as 8-15% in jobbing foundries – cannot
be attributed to poor methoding and process variability alone. Most castings are
designed for manufacture, not for manufacturability. Many defects like shrinkage
porosity, hot tear, and cold shut originate from poorly designed part features
(isolated junction, constrained internal feature, long thin section, respectively).
Foundry engineers partially tackle the problem by tweaking the part design (for
example, increasing a fillet radius or padding a thin wall), but incur additional and
avoidable costs of machining and productivity loss. Ideally, design for
manufacturability (DFM) should be carried out early by product engineers
(foresight), instead of late DFM currently practiced by casting suppliers (hindsight).
Unfortunately, designers lack foundry knowledge, and foundry engineers lack design
rights. We present a collaborative system for achieving perfect castings – high-
quality with frugality –by integrating part, tooling, methods and process
optimization, and providing feedback loops to part design. Major control parameters
include: wall thickness, junctions and hole diameter (part design phase), parting line,
cores and mold cavity layout (tooling design), feeding and gating system (methods
design), and process settings (manufacturing). Each subsequent phase provides more
information and feedback regarding part quality and cost to the designer, allowing
design improvements for manufacturability without affecting functionality

3.1.4] Quality Tools to Reduce Crankshaft Forging Defects: An

Industrial Case Study

Pankaj Chandna1 et al., Crankshafts are the most important loaded components in
the case of an automobile. In order to achieve required mechanical properties most
of crankshafts for automobile are forged with micro alloyed steel. Usually, the
shapes of crankshafts are complex, and many defects are induced during the process
of crankshaft forging such as under-filling, laps and folds etc. In this work the
forging analysis of six-cylinder crankshaft produced by hot forging having engine

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bore of ninety-seven mm popularly known as 697 crankshafts manufactured by

TATA Motors, Jamshedpur INDIA (previously known as TELCO) used in trucks
and buses is being made. Forging analysis is being made to explain that how the
defects appear and how to prevent them. This analysis can be easily done with the
help of various quality tools used for quality improvement process. With the help of
Pareto diagrams, which are mostly used to identify critical areas, the forging defects
of the crankshaft have been prioritized by arranging them in decreasing order of
importance. Then cause and effect diagram is being applied to explore possible
causes of defects through brain storming session and to determine the causes which
has the greatest effect. Corrective measures are being suggested to overcome the
forging defects of the 697 integral counterweight crankshafts. Finally, few remedial
measures and suggestions have been provided for the existing crankshaft production
line in the forging shop. It is also concluded that the proper implementation of the
proposed corrective plan may reduce the present rejection rate from 2.43% to 0.21%
and rework from 6.63% to 2.15%

3.1.5] Defect Reduction with the Use of Seven Quality Control Tools
for Productivity

Memon et al.:The goal of zero defects is pursued by many manufacturing and service
companies. In this regard, statistical tools are being used for defect reduction leading
to productivity improvement. In this work, seven traditional QC tools (flow chart,
check sheet, histogram, Pareto chart, cause, and effect diagram, scatter diagram and
control chart) have been developed and implemented in an automobile company to
assess and improve the defect reduction level in the assembly line. Chassis and trim
lined were selected for data collection to assess and improve the defect level for
productivity improvement. It was found from the results that after the successful
implementation of the QC tools, the defect level reduced by 90% (from132 to 13
defects) at the chassis line. Similarly, the defect level was reduced by 80% (from 157
to 28 defects) at the trim line. The automobile company implemented only a few of

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the seven QC tools in their assembly line. It is suggested that the company may need
to manage a mechanism for the implementation of all seven QC tools in every section
of the company.

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Literature Summery
From above research papers and case studies we understand about various processes
for camshaft manufacturing and defect reduction methods which can be implemented
to reduce the defect in camshaft manufacturing process like SIX SIGMA, PIVOT
CHARTS, FMEA (Failure mode effect analysis) SHEETS, DMAIC (Define, Measure,
Analysis, Improve, Control) which can help us achieve the target of defect reduction
in camshaft manufacturing process.

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Chapter 4
Data collection
4.1] PROCESS INVOLVED IN MANUFACTURING OF CAMSHAFT

Fig 4.1 process flow chart.

Following figure shows flow of all the processes used in manufacturing of camshaft,
while crack and burn tests are used to detect the defect caused during manufacturing
process.

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Keyway milling :
Keyway milling is the process of producing a keyway using the milling
machine. Key refers to a type of part used in mechanical transmission, mainly
for the circumferential fixation between the shaft and the parts on the shaft to
transfer torque. Some keys can also realize the axial fixation or axial movement
of the parts on the shaft. The groove or slot machined for installing the key is
called keyway, which is usually cut along the axis of the cylindrical surface of
a shaft. When you put a pulley on a shaft, the keyway can prevent the pulley
from rotating on the shaft. The keyway can be divided into open type, semi-
open type, and closed type.

Fig 4.2 keyway milling

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Deburring:
Deburring is the process of removing the small imperfections known as burrs from
machined metal products. Machining processes shape a piece of metal in different
ways. Stamping, for instance, presses the workpiece in a die set, while milling uses a
rotating tool to shave metal off a workpiece.

Induction hardening:
Induction hardening is a type of surface hardening in which a metal part is induction-
heated and then quenched. The quenched metal undergoes a martensitic
transformation, increasing the hardness and brittleness of the part. Induction
hardening is used to selectively harden areas of a part or assembly without affecting
the properties of the part as a whole.

Fig 4.3 induction hardening

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Tempering :
Tempering is a type of heat treatment used to increase the toughness of certain metals,
most commonly iron-based alloys like steel. The metal being treated, using this
process, is heated under its critical point temperature and then air-cooled.
In this process the part is kept in tempering furnace for 3 hours at 230 degrees.

Fig 4.4 tempering machine.

Shot blasting:
Shot blasting is a method used to clean, strengthen (peen) or polish metal. Shot
blasting is used in almost every industry that uses metal, including aerospace,
automotive, construction, foundry, shipbuilding, rail, and many others. There are two
technologies used: wheel blasting or air blasting.

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Fig 4.5 Shot blasting

Straightening :
Straightening can be performed on forged, finished or tubular shafts where cams are
clamped. Generally, up to 6 straightening points are required. For a precise analysis of
the pitch diameter and a consequent accurate straightening, the machine is equipped
with a Master device for each groove. Machine size depends on the section and length
of parts.

Fig 4.6 Straightening

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Cam grinding :
Cam grinding is a form of cylindrical grinding. Most cam grinding machines are
custom fitted to the part being ground. In generating cam shapes, some variation in
grain and grade can improve results. Cam grinding wheels are available for both steel
and cast.

Fig 4.7 Cam grinding

Camshaft Burn test :
Grinding thermal damages, also known as grinding burns, will shorten the fatigue life
of critical, dynamically loaded components and can lead to severe failures. Grinding
burns occur when the energy from grinding produces too much heat. Grinding burn
decreases hardness and causes tensile residual stress.Camshaft burn test is a
inspection technique is which the camshaft is checked for burns caused during the
grinding process. Three type of acids are used and the cams are wiped with acids
which makes the burn on camshaft visible.

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Crack testing :
Crack testing is a process in which ultra violate black lights are used in conjunction
with fluorescent dye penetrants and magnetic particles for highlighting defects in
metals.it is a non destructive technique of inspection.

Fig 4.7 Crack testing

Super finishing also known as micromachining, and short-stroke honing, is

a metalworking process that improves surface finish and work piece geometry. This is
achieved by removing just the thin amorphous surface layer left by the last process
with an abrasive stone or tape; this layer is usually about 1 μm in magnitude. Super
finishing, unlike polishing which produces a mirror finish, creates a cross-hatch
pattern on the work piece.

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4.2] DATA COLLECTION

Fig 4.8 Rejection Data from January 2018 to August 2022

This sheet contains the data of defects caused which gives us information about the
rejected camshafts and the cause of rejection. This data consists of information from
January 2018 to August 2022. The remaining data is attached in annexure.

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4.3] Applying pivot chart to the rejection data for understanding the
amount of defects caused in each process

Fig 4.9. Data of camshaft Rejection from 2018

Following pivot chart shows of defects that are caused in manufacturing process on
various machines from 2018.

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4.3] Camshaft expected and actual rejection data in parts per million.

Fig 4.10 Camshaft rejection action plan.

Following graph shows that the actual defects produced are more the expected defects.
the expected defects in 2021 was 6488 but the defects caused were 22795 but after
implementation of defect reduction techniques the defect are reduced then the
expected defects ie. 14384 while the expected defect were 17096 parts per million.

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Chapter 5

QUALITY CONTROL TECHNIQUES

5.1] Poka-yoke:
it is a Japanese term that means “mistake-proofing” or “inadvertent error prevention”.
applied by Shigeo Shingo in the 1960s to industrial processes designed to prevent
human errors Poka-yoke can be implemented at any step of a manufacturing process
where something can go wrong, or an error can be made.

Benefits of poka-yoke:

 Less time spent on training workers.

 Elimination of many operations related to quality control.
 Unburdening of operators from repetitive operations.
 Promotion of the work improvement-oriented approach and actions
 A reduced number of rejects
 Immediate action when a problem occurs
 100% built-in quality control
 Preventing bad products from reaching customers
 Detecting mistakes as they occur
 Eliminating defects before they occur.

Procedure for mistake proofing.

1) Obtain or create a flowchart of the process. Review each step, thinking about
where and when human errors are likely to occur.
2) For each potential error, work back through the process to find its source.
3) For each error, think of potential ways to make it impossible for the error to occur.
Consider:
4) Elimination: eliminating the step that causes the error.
5) Replacement: replacing the step with an error-proof one.

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6) Facilitation: making the correct action far easier than the error.
7) If you cannot make it impossible for the error to occur, think of ways to detect the
error and minimize its effects. Consider inspection methods, setting functions,
and regulatory functions expanded on below.
8) Choose the best mistake-proofing method or device for each error. Test it, then
implement it. Three kinds of inspection methods provide rapid feedback:
9) Successive inspection is done at the next step of the process by the next worker.
10) Self-inspection means workers check their own work immediately after doing it.
11) Source inspection checks, before the process step takes place, that conditions are
correct. Often it’s automatic and keeps the process from proceeding until
conditions are right.

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5.2] SIX SIGMA:

Six Sigma is a method that offers organizations tools to improve their capabilities in
managing their businesses. This increase in performance and decreasing process
variation, it is possible to reduce defect rates, improve employee morale, and improve
the quality of products or services, which all contribute to a higher level of
profitability.

It consists of 5 stages:
Define: define the problem by developing problem statement.
Measure: collect the data about how the process currently performs.
Analyze: closely examine the process and identify the cause of problem
Improve: develop various solutions, select the best solution & implement it.
Control: ensure the process is being managed and monitored properly.

Fig 5.1 Camshaft rejection action plan.

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5.3] FMEA ( FAILURE MODE EFFECT ANALYSIS ) SHEET:

FMEA stands for “failure mode and effect analysis”. it is a structured way to identify
and address the problem or failure and its resulting effect on the system or the process
before the event occurs.

The basic steps to using the FMEA Worksheet are:

1. Identify all failure modes.

2. Consider the root causes.
3. Assess the risk of the failure (severity, occurrences, and detection).
4. Create an RPN (risk priority number) and rank the failure modes.
5. Eliminate the risks

The FMEA process is composed of a cross-functional collaborative team composed of

members in engineering, manufacturing, quality, operations, procurement, and other
functions with a process manager responsible for managing the project.

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5.4] PARETO CHART:

A Pareto chart derives its name from Vilfredo Pareto, a noted Italian economist, is a
type of chart that contains both bars and a line graph, where individual values are
represented in descending order by bars, and the cumulative total is represented by the
line. The chart is named for the Pareto principle.

Fig 5.2 Pareto Chart

Steps of pareto analysis

1.Identify the problem or problems.

2.List or identify the cause of the issues or problems, noting that there could be
multiple causes

3.Score the problems by assigning a number to each one that prioritizes the problem
based on the level of negative impact on the company

4.Organize the problems into groups, such as customer service or system issues
Develop and implement an action plan, focusing on the higher scored problems first,
in order to solve the problems.

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5.5] LAYERED PROCESS AUDITS:

The final tool for reducing defects and costs is high-frequency auditing, a best
practice for driving quality improvements. An example would be implementing a
layered process audit (LPA) program, which involves all layers of personnel in
verifying high-risk processes

A layered process audits program includes three critical things:

 Auditors pulled from across the organization, including all levels of

management

 A set of simple audits, which do not require specialized knowledge to conduct,

focused on high-risk processes

 A system of reporting and follow-up that exposes problem areas and ensures
containment and corrections are put – and held – in place.

Process For Implementing a Layered Process Audit

 Assemble a Team,Decide who will be on the audit team.

 Identify Process Layers.

 After forming a team, you need to identify the layers of the process being
audited.
 Develop Audit Guidelines.
 Carry Out the Layered Process Audit Program.
 Analyze and Implement Corrective Action.

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5.6] KAIZEN:
Kaizen focuses on eliminating waste, improving productivity, and achieving sustained
continual improvement in targeted activities and processes of an organization.it is an
improvement processes, often is considered to be the "building block" of all lean
production methods.
3 pillars of kaizen
 Housekeeping.
 Elimination of Waste. Eliminating waste is the second main pillar of Kaizen.
 Standardization. Standardization is the process of developing standards to which
production is performed.

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SELECTION OF MOST SUITABLE DEFECT REDUCTION

TECHNIQUE:

We select poka-yoke technique for defect reduction as it is most effective in defect

reduction compared to other methods and helps us reduce the defect during
manufacturing

Fig 5.3 poka yoke techniques

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Chapter 6
6.1] Selecting the machine with maximum defect.
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Ka
Te

Ka

Defect Qty 104 68 44 35 30 20 19 15 13 11 10 8 8 18

Percent 26 17 11 9 7 5 5 4 3 3 2 2 2 4
Cum % 26 43 54 62 70 75 79 83 86 89 92 94 96 100

Fig 6.1 Pareto Chart

sr no. defect category defect quantity

1 tempering furnace 104
2 manual mistakes 68
3 EMA#1 44
4 kataoka milling 2 35
5 GH 30
6 landis 4 20
7 EMA 19
8 landis 3 15
9 GNC 13
10 junker 11
11 landis 10
12 kataoka milling 3 8
13 other 8

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After applying pareto chart to the data collected from year 2022 we get to know that
maximum number of defects are produced in tempering furnace followed by manual
mistakes, therefore we select tempering furnace for implementing the poka-yoke.

Fig 6.2 Tempering furnace.

Tempering is a heat treatment technique applied to ferrous alloys, such as steel or cast
iron, to achieve greater toughness by decreasing the hardness of the alloy. The
reduction in hardness is usually accompanied by an increase in ductility, thereby
decreasing the brittleness of the metal. Tempering is usually performed
after quenching, which is rapid cooling of the metal to put it in its hardest state.
Tempering is accomplished by controlled heating of the quenched work piece to a
temperature below its "lower critical temperature", the camshaft is kept in tempering
furnace at the temperature of 230° for three hours.

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After analyzing we understood that the defect in tempering is caused due to the
improper heating of camshaft from all the sides which is leading to formation of
cracks on the surface of camshaft which lead to rejection.

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Chapter 7
Implementation
The previous layout of furnace included only one fan for the distribution of air to the
workplace, which lead to improper heating of camshaft from all the side which led to
the crack formation.

Previously implemented Poka-yoke:

Door of the furnace is locked and cannot be opened until the operation is completed.
The fans start immediately as the machine starts operating.

Fig.7.1 Previous Layout

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7.1] Poka-Yoke applied:

 We increase the number of fans for the proper distribution of air to the
workspace.
 To reduce the defect, we provide interlocking between fans of furnace for the
proper distribution of air flow over the surface of camshaft. This leads to
proper distribution of heat in furnace which leads to proper heating of
camshaft and plays a major role in proper hardening of camshaft which
reduces the crack formation on the camshaft.
 The fans run continuously until the machine is externally stopped.

Fig 7.2 Modified layout

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Chapter 8

IMPLEMENTATION OF POKA-YOKE ON VARIOUS

MACHINES IN COMPANY.

Sr Manufacturing Section No of poka-yoke

no. implemented.
1 Connecting Rod 21
2 Cylinder Block 54
3 Cylinder Head 33
4 Heat Treatment 5
5 PT 7
6 V28 Cylinder Block 13
7 Camshaft 6
TOTAL POKA-YOKE 139
IMPLEMENTED

This are the various poka-yoke implemented on various machines in a companys

various sections which includes connecting rod, cylinder block, cylinder head, heat
treatment, V28 cylinder block and camshaft.

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Fig 8.2 Currently working Poka-Yoke in company

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CHAPTER 9
Conclusion

Fig 9.1 Pareto chart after defect reduction

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9.1]Table of results after implementation of poka yoke on tempering

furnace.

SR NO. DEFECT CATEGORY DEFECT QUANTITY

1 Tempering Furnace 0
2 Landis 4 39
3 Landis 3 38
4 Manual Mistakes 25
5 Katoka Milling 21
6 GH induction hardening 12
7 Kataoka Milling 1 11
8 Junker 5
9 Assembly Return 3
10 Other 5

Successfully reduced the defect in camshaft during tempering process from 104 to 0
by implementation of Poka-Yoke quality reduction technique.

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REFERENCES:

[1] A S M Handbook (1988), Forming and Forging; 9th edition, vol. 14, The Material
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[5] Fiyikawa S. (2000), Application of CAE for hot forging of automotive

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[7] Grant E.L., Leavenworth R.S. (2000), Statistical quality Control; Tata McGraw-
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[9] Lertsirarungsun T., Ruangsilasingha T. (1987), Practical approach to determine

the optimum hot forging process concerning power input, SEAISI Q 16(3); 54–64

[10] Metals park Ohio (1986), Failing Analysis and Prevention; A S M Handbook,
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[11] Paul F.S. (2002), Modeling gas quenching of a carburized gear; Heat Treatment
Met. 29(2); 29–32.

[12] Takemasu T., Vazquez V., Painter B., Altan T. (1996), Investigation of metal
flow and perform optimization in flashless forging of a connecting rod; Journal of
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[13] Thomas B.G., Semiatin S.L., Vollmex C. D. (1985), Forging Handbook;

American Society for Metals.

[14] Xinhai Z., Guoqun Z., Guangchun W., Tonghai W. (2002), Optimal perform die
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[15] Zhichao L., Ramana G., Rajiv S. (2002), Optimum design of heat transfer
coefficient during gas quenching process by using response surface method; Journal
of Machine Tools Manufacturing 42(5);[16]F.Britesa*, C. Malçaa,b, F.Gaspara,
J.F.Hortaa, M.C. Francoa, S. Biscaiaa, A. Mateusa

"Cork Plastic Composite Optimization for 3D Printing Applications,"

Procedia Manufacturing 12(2017) 156 – 165
[16]Tiantian Li, Lifeng Wang "Bending behavior of sandwich composite structures
with tunable3D-printed core materials." Composite Structures 175 (2017) 46–57

[17]Review On Multiaxial Fatigue CriteriaM. F. Radzi, T. T. Mon andM.M. Rahman

[18]Application of Plastics CAE:Focusing on Impact Analysis by Masaaki

TSUTSUBUCHI,TomooHIROTA,YasuhitoNIWA, Tai SHIMASAKI

[19]Strain sensing behaviour of 3D printed carbon black filled ABSMichael Dawoud

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[20]"Co-Continuous Composite Materials for Stiffness, Strength,and Energy

Dissipation" byLifengWang, Jacky Lau, Edwin L. Thomas, and Mary C. Boyce.

[21]"RepRapable Recyclebot: Open source 3-D printable extruder forconverting

plastic to 3-D printing filament" Aubrey L. Woerna, Joseph R. McCaslin b, Adam M.
Pringle c, Joshua M. Pearce [8]method to predict the ultimate tensile strength of 3D
printing polylacticacid (PLA) materials with different printing orientations by
Tianyun Yao, Zichen Deng, Kai Zhang, Shim

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