Basic Problem Solving (BPS) -

Project Document

Project Title Q improvement of SWC mounting CD.

Process/Product Process

Project Leader Madan Giri Sponsor Name Naushad Ahamad

(Mob No.) (9761160225) (Mob No.) (9557392200)
PS Facilitator/s Naushad Ahamad
Project Code MMT/2022/01
Name (9557392200)

Unit Press & Fabrication Function Process QA

Start Date (Actual) 10.10.2022 End Date (Actual) 04.11.2022

Hemant Mehra (QA)

Mukesh Kumar (Tool Room)
CFT Members
Avinash Sharma (Production)
Ujala saxena (Engineering)

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 AL-BPS Methodology

Charter, Teaming, Pareto, Project

All possible ‘X’s Problem Management, Matrix diagram

Gemba visit, Check sheet, SPC,

Observation
Stratification, Histogram

Analysis Stratification, Pareto, Fishbone diagram,

Scatter diagram, Concentration chart, SPC

Brainstorming, Solution development, Risk & Cost

Action benefit analysis, Pilot implementation

Check Check sheet, Histogram, Pareto, Run charts, Full

scale implementation, SPC

Standardize Check sheet, SPC

Conclude Pareto, Matrix diagram, Finance vetting, Way forward

Few ‘X’s
Acknowledgements, Future projects

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 Project Selection Grid – 2x2 Matrix

Advanced Problem Solving Zone

(APS)

Project selection
Grid

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 Step 1 : Problem Identification
Project Charter
Project MMT/2022/01 Project Madan Giri Unit / Press & Fabrication
Code Leader Name Function
Project Title Q Improvement of SWC mounting CD.
Problem Hole CD observed 305.48mm against Spec of 300.00mm.
Definition

In Scope CTG ETC Out of Scope Rest Model

Project Metric PPM Baseline Zero Target Zero Benchmar Zero

Goal k
Cost Savings (INR) < 5 Lakh / annual Intangible 1. Zero defects 2. cost Saving
Benefits 3.Productivity increased

Customer AL-PNR Linkage to Reduction in Customer PPM to 20

Sponsor KRA for FY23
Time Lines (Planned) Project Start 10/10/2022 Project End date 04/11/2022
date
Problem Selection 08/10/2022 Observation 10/10/2022 Analysis 17/10/2022 Action 26/10/2022

Check 28/10/2022 Standardize 02/11/2022 04.11.2022 Lead Time 28 Days

Conclude (Days)

Support Required Timely approval from management.

Approvals Sponsor: Naushad Ahamad Plant Head: Naushad Ahamad PS Facilitator: Naushad Ahamad

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 Project CFT – Details
Time
# Name (with Initials Roles & Responsibility Function commitment Photo
& mobile no) (Stamp size)
required

Madan Giri
1. Project Leader Quality 2 hour per day
(9761160225)

2. Hemant Mehra Team Member Quality 2 hours per day

(7906159109)

Mukesh Kumar
3. Team Member Tool Room 2 hour per day
(9899983051)

Avinash Sharma
4. Team Member Production 2 hour per day
(9758669207)

Ujala Saxena Team Member Development 2 hour per day

5.
(9410589789)

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 Gantt Chart
Project Planning – Plan Vs Actuals
Timelines  Plan /
Oct-22/W1 Oct-22/W2 Oct-22/W3 Oct-22/W4 Nov-22/W1
/ Phase Actuals

P          
Problem
A          
P          
Observation
A          
P          
Analysis 
A          
P          
Action
A          
P
Check
A
P
Standardize
A
P          
Conclude
A          

Legend (for Actuals row): Task Completed All cells in Green color
Task initiated but not yet completed All cells in Yellow color
Task not yet initiated All cells in Red color
Observatio Standardiz
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 Problem Background & Impact

Pareto

Inference : Major defect observe in SWC “C” plate bottom at bending stage.

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 VOC & Defects “as-is” – Photos

Dear MMT Team,

This is to inform you that , fitment issues reported in every vehicle has a issues at
line in SA of Spare wheel carrier MB, Part No :- MB121001_7204543.
Hole CD dim observed 290.05+15.43(Hole dia)=305.48mm, Against Spec of
300.00mm.
 

Inference : Hole CD dim observed 290.05+15.43(Hole dia)=305.48mm, Against Spec of 300.00mm.

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 Step 2 : Observation
Process Flow Diagram
• Process flow of “C” plate bottom & Welding assembly.

Sub Assembly
of {(Main Plate
+ Stiffener
Strip Shearing Cross Plate + 4 Hole Inspection of
Bending of “C”
of “C” Plate Shearing of “C” Top C Plate + main part at
Plate Bottom
Bottom Plate Bottom 1 Hole Top C Pre-PDI.
Plate + C Plate
Bottom +
Gusset)}

Inference : SWC mounting CD observe out of spec after welding due to bending length excess of “C” Plate
Bottom

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Awareness Creation – Initiatives

Communication
# Initiative Frequency Gemba Mode Resp EDC RYG
(Mail/Displays/Spee
ch etc.)
Project Metric Press shop,
Twice in a Meetings /
1 Trend Monitoring Welding Shop & QA - G
& sharing with CFT week PDI Speech

Press shop,
Problem discuss 2 hrs. per Welding Shop &
2 with CFT day PDI Meetings QA - G

Press shop,
3 month Welding Shop &
3 OPL & Q-Alert Displays QA - G
validity PDI

Inference :
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 Data Collection Plan

Type of Data Data Who will Data Method

Inputs / Sample
Formula (Variable / Source Collect Collection of Collecting
Outputs Discrete) & Location Size the Data? Frequency data

Data Collection
Outputs  Variable  Press Shop  50 no's  QA Engineer 2 Hours  Continues Part
Check Sheet Dim 235
inspection report.

Data Collection
Inputs Check Sheet  Variable  Weld Shop  50 no's  QA Engineer 2 Hours  Continues Part

Data Collection
Outputs  Variable  Weld Shop  50 no's  QA Engineer 2 Hours  Continues Part
Check Sheet CD 300 mm
report.

 
Data Collection
Outputs Check Sheet  Variable  PDI  100 %  QA Inspector 100 % 100 %

           

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Gemba Observation (Defects / Abnormalities)

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 CFT Meetings – Record of Discussions

Review / Total no of Total no of

Place / Members Participated Embed
No Date Location Discussion (Initials in CAPS) Members Members MOM
with Planned Attended
Madan Giri
MMT-3 / Hemant Mehra
1  08.10.2022 Rudrapur Group Leader  Avinash Sharma
05  05
Ujala Saxena

Madan Giri
MMT-3 / Hemant Mehra
2  10.10.2022 Rudrapur Group Leader  Avinash Sharma 05  05
Ujala Saxena

Madan Giri
Hemant Mehra
MMT-3 / Facilitator &
3  17.10.2022  Rudrapur
Group Leader
Mukesh Kumar 05  05
Avinash Sharma
Ujala Saxena

Madan Giri
Hemant Mehra
MMT-3 / Facilitator &
4 28.10.2022
Rudrapur Group Leader
Mukesh Kumar 05  05
Avinash Sharma
Ujala Saxena

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 Step 3 : Analysis
Brainstorming / Idea Generation
Topic:  Q Improvement of SWC mounting CD.
Date: 17.10.2022 Venue: Conference Room
Participants Name:
1. Madan Giri 4. Ujala Saxena
 2. Hemant Mehra  5. Mukesh Kumar
 3. Avinash Kumar  6.
 Ideas:   Correction required in tooling of “C” bracket to control drawing requirements.
 6. Tick mark at all 4 holes after gauge
 1. Machining block to be required.
inspection at PDI.
 2. Stopper length to be increased.  7.
 3. Stopper resting face to be flat.  8.
4. Stopper to be fixed with Dowling & Bolting. 9.
 5. CD location to be required in load testing
 10.
fixture.
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 Fish Bone Diagram

Environment Method
Machine

-- Uneven machine -- Low visibility at work -- Stopper loose/improper

pressure station
-- Stopper Damage during
-- Machine in poor -- improper 5S Stopper miss--
operation.
Motor belt tension working order / PM not done
improper------ -- Stopper reference is not
-- Machining oiling not -- High climatic
temp variation proper
done

Storage deterioration -- CD 305.48

observe
against spec
300mm.
Operator skill low --

-- Checking instrument not

Lack of awareness about -- Wrong Material calibrated
process controls -- selection
-- SOP not available for inspection

Limited understanding for -- Wrong selection/ alteration -- inadequate inspection

part inspection -- of process parameter control

-- Inspection Skip at final

stage.

Man Material Measurement

Inference :
Observatio Standardiz
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 Why-Why Analysis

• Hole CD observed 305.48mm against Spec of 300.00mm.

Why

• After welding mounting CD observe 302 to 306mm (i.e.-

Bottom "C" bracket width observe more 235 to 238 mm
Why against spec 235mm).

• Part bending reference was wrong.

Why

• Part bending stopper was loose.

Why

• Part bending stopper was mount with bolting only.

Why

Inference : Part bending stopper was mount with bolting only.

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 Root Cause/s – Photo/s

Stopper was mount with bolting only. Sheet metal block available & gap Part no resting at front side
observe during part resting. during 2nd bending.

Part thickness rest on stopper less than 6mm CD 300mm locating provision not
during bending due to less thickness of stopper. available at load testing stage.

Inference :

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 Tollgate Review (Till Analyze phase)

Phase Key Milestones RYG Remarks (if any)

Charter Finalization & Sign off by Sponsor G

Problem
Estimate cost benefit in INR G
Identification

Voice of Customer G

Gemba Observation G
Observation
Data collection plan formulation G

CFT Meetings / Discussion as per Plan G

Analysis Awareness Creation / Trend monitoring as per Plan G

Root Cause Analysis (RCA) G

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 Step 4 : Action
Solution Development & Consensus
Topic: Q Improvement of SWC mounting CD. 
Date: 18.10.2022 Venue: Conference Room
Participants Name:
1. Madan Giri 4. Ujala Saxena
 2. Hemant Mehra  5. Mukesh Kumar
 3. Avinash Kumar  6.
 Ideas:   Improvement points implemented in “C” bracket tool.
 6. Tick mark implemented at all 4 holes after
 1. Machining block provided in tool.
gauge inspection at PDI.
 2. Stopper length increased.  7.
 3. Flat resting face stopper provided.  8.
4. Stopper fixed with Dowling & Bolting. 9.
 5. CD location Provided in load testing fixture.  10.

Inference :
Observatio Standardiz
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 Solution Selection

Time to Difficult
Cost of
implement to
Implementatio Grand
(1-10) implemen
# Solutions n 1= least t (1-10) Total Rank
(1-10)
1= least cost time 1= least
required difficult

1 Machining block provided in tool. 2 2 2 6 1

2 Stopper length increased. 2 2 2 6 1
3 Flat resting face stopper provided. 2 2 2 6 1
4 Stopper fixed with Dowling & Bolting. 2 2 2 6 1
5 CD location Provided in load testing fixture. 3 4 4 11 2

Tick mark implemented at all 4 holes after

6 gauge inspection at PDI. 2 2 2 6 1

Note: List all Potential Solutions with CFT and then brainstorm for ranking of the factors on a Microsoft Excel

scale of 1 to 10. Each one should individually rate first, and finalize with the consensus of CFT. Worksheet

Inference :

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 Risk Analysis
(Change Management actions)
# Risk mitigation Respons- Approval Deadline RYG
Solution Potential risks Statu
. plan -ibility Authority Date
s

1 Machining block
provided in tool
Wear out / Tapper  PM plan  Prahlaad Mukesh  28.10.2022  G

2 Stopper length
increased
Wear out / Tapper PM plan  Prahlaad Mukesh 28.10.2022 G

3 Flat resting face

stopper provided
Wear out / Tapper PM plan  Prahlaad Mukesh 28.10.2022 G

4 Stopper fixed with Wear out / Tapper PM plan  Prahlaad Mukesh 28.10.2022 G
. Dowling & Bolting
5 CD location provided Wear out / Tapper
. in load testing fixture
PM plan  Prahlaad Mukesh 28.10.2022 G

Tick mark
6 implemented at all 4
holes after gauge
Skipped
Sustenance action
Check sheet
Rajesh Madan 15.10.2022 G
inspection at PDI

Inference :
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 Pilot Implementation Plan
(Change Management actions)
Sample Size
Respons- Deadline RYG
# Counter Measure Pilot area with -ibility Date Status
Frequency

1  Machining block provided in tool

2  Stopper length increased

 Press Shop
100 no's lot  Production  30.10.2022  G
Engineer  
3  Flat resting face stopper provided

4 Stopper fixed with Dowling & Bolting

CD location provided in load testing 100 no's per Production

5 Assembly area shift  30.10.2022 G
fixture Engineer

Tick mark implemented at all 4 holes Quality

6
after gauge inspection at PDI PDI area 100 %
Inspector
30.10.2022 G

Implementation From date :  28.10.2022 To date: 30.10.2022

Inference : Pilot lot Implemented.
Observatio Standardiz
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 Full scale Implementation – Plan & Status

Sample Size
# Counter Measure Plant / Area / with Respons- Deadline RYG
Line -ibility Date Status
Frequency
1  Machining block provided in tool

2  Stopper length increased

 Press Shop 100 %  Production  30.10.2022  G
Engineer
3  Flat resting face stopper provided

4 Stopper fixed with Dowling & Bolting

CD location provided in load testing Production
5 Assembly area 100 % Engineer  30.10.2022 G
fixture
Tick mark implemented at all 4 holes Quality
6 PDI area 100 % 30.10.2022 G
after gauge inspection at PDI Inspector

Implementation From date :  08.10.2022 To date: 04.11.2022

Inference :

Observatio Standardiz
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 Tollgate Review (Action & Check phase)

Phase Key Milestones RYG Remarks (if any)

Solution Development & Consensus G

Solution Selection G
Action
Risk Analysis G

Pilot Plan G

Effectiveness Check G

Check Full Scale Implementation G

CFT Meetings as per Plan G

Observatio Standardiz
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 Before Vs After Improvement

Before After

Sheet metal block available

Machining block with proper
& gap observe during part
resting provided.
resting.

Inference : Eliminate gap during part resting.

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 Before Vs After Improvement

Before After

Part no resting at front side Stopper length increased by

during 2nd bending. 200mm.

Inference : Maintained excess length of C plate bottom.

Observatio Standardiz
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 Before Vs After Improvement

Before After

Part thickness rest on

stopper less than 6mm
Part rest on stopper 100%.
during bending due to less
thickness of stopper.
Inference : Eliminate part shifted during 1st bending.

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 Before Vs After Improvement

Before After

Stopper fixed with bolting &

Part bending stopper was
Dowling to eliminate the
mount with bolting only.
possibility of loose condition.

Inference : Stopper fixed with bolting & Dowling to eliminate the possibility of loose condition.

Observatio Standardiz
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 Before Vs After Improvement

Before After

CD 300mm locating provision

CD 300mm location provided at
not available at load testing
load testing stage.
stage.

Inference : Stopper fixed with bolting & Dowling to eliminate the possibility of loose condition.

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 Sustenance Audit plan

Reporting Non-
# Audit Check point Auditee Auditor When? Where?
conformance to whom?

Tick mark
implemented at all 4
1 holes after gauge Gurudev Rajesh  Daily  PDI  Madan Giri
inspection at PDI

     

Inference :

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 Voice of customer (VOC) – After

• No fitment issues raised after implementation actions at cause side or

detection side.

Inference : No Customer complaint for the defect phenomenon.

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 Tools Used (as applicable)

Key Tools Problem Observation Analysis Action Check Standardize Conclude

Project Charter
Gantt Chart √
Pareto Analysis √
VOC √
Gemba Observation √
Process Flow diagram √
Check Sheet
C & E diagram √
Brainstorming √
Data Stratification
Histogram
Scatter Diagram
Concentration Chart
Risk Analysis √
Cost Benefit Analysis
SOP/WI/Control Plan
Visual Controls
Poka Yoke
Control Charts
VOC √
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 Acknowledgements

1. Good job done to eliminate mounting CD fitment issue.

2. Good initiative taken by Engineering Team to implementation of mounting CD detection
with Load testing.

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 Preview of Advanced Problem
Solving (APS)

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 VOC & Defects “as-is” – Photos

Blister issue in
coming supply part
HUB CAP FOR
DUMMY
AXLE_F1106613.
 

HCFB mtg bracket paint peel off from top.

Paint peel off observed on SA of Spare wheel

carrier MB during ALVES audit ,Part No :-
MB121001.

Inference : Blister & peel off issues in parts during ALVES audit.

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 Root Cause/s – Photo/s

7 Tank PT process with manual

Paint booth with manual controls.
controls.

Inference : Manual controls at Paint & PT process.

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 Before Vs After Improvement

Before After

Paint booth with manual

Automation paint booth.
controls.

Inference : Eliminate gap during part resting.

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 Before Vs After Improvement

Before After

7 Tank PT process with 11 Tank PT process with fully

manual controls. automation.

Inference : 7 tank manual PT process replaced with 11 tank fully automation.

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 Journey of Excellence continues …..

Thank You ….

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