Adithya Automotive Applications Pvt.Ltd.

21/12/2013
Root Cause Analysis
Gap between Runner Tube and Sub Frame

Author: J.Udayanjani.P





Gap between runner tube
and sub frame
en
ethods
aterials
a!hine easurement
Inadequate
training
Attitude
towards
work
Unskilled
Process
ariations
!oss of
time
Inadequate
met"odolog#
Policies
use
arious $uppliers
%&' steel
(ualit#
(ualit# of consumable
electrode
$pecification
)ariations
Inadequate
standards
Inspection
le)el
Insufficient
*e)ices
Improper
+ooling
,lamping
and fi-ture
.ac"inabilit#
/rientation
,ause and 0ffect *iagram 12is"bone *iagram3
"#$%& A'A(&S)S

Root Cause:#
14 +"e appearance of "ot rolled 5 cold rolled steel ma# look similar6 but on keen in dept" obser)ations6 )ariations can be
witnessed&
24 $teel wit" 0&78 of carbon will "a)e good strengt" in bending as well as torsion9 t"is "ardens t"e surface la#er b#
impro)ing t"e resistance to wear wit" 0&:8 .n 5 0&18 $ilicon&
34 .etals "a)ing )er# low carbon content consist of ferrite grains "a)ing tensile strengt" of 2;0 </mm26 similarl# carbon at
0&786 w"ic" is =ust o)er "alf t"e area of micro structure consists of pearlite wit" a strengt" of ;70 </mm26 carbon at 0&:8
micro structure will be completel# pearlitic and attains a ma-imum strengt" of :;0 </mm2&
Corre!ti*e + Pre*enti*e A!tion:#
>"# 1?
*ue to .ac"inabilit#6 i&e due to bending
process @If/ If not4
>"# 2?
$"earing of s"eet b# cut to siAe6 @If/ If not4
>"# 3?
$"eet dimensions like diagonal6 lengt" 5
widt" consideration6@If/ If not4
>"# 7?
Incoming $teel (ualit# )ariations6 @If/ If not4
14 (ualit# +est ,ertificate of Incoming $teel from t"e suppliers6 must be )erified in accordance wit" I$//BI$ $tandards
24 %ardness of steel "as to be c"ecked b# "ardness test equipments if a)ailable6 else t"e material needs to undergo lab testing
for arri)ing t"e required details6 t"e ma-imum time allocation for lab testing s"ould be 2C3 da#s in ma-imum&
34 +est results acquired needs to be furnis"ed to t"e Production department along wit" (ualit# department for information and
necessar# action&
74 $tringent policies designed / to be designed b# t"e management6 wit" a mandate pursuant to eac" and e)er# department for
attaining consistent qualit# outcomes&



Technique: Cold Rolled
Standard:ASTM, AISI, DIN Technique: Hot Rolled
Surface Treatment: Coated Standard:ASTM, AISI, DIN
Special Use: High-strength Steel Plate Surface Treatment: Annealed,
Special Use: Welding Special steel
"#$%& A'A(&S)S
Root Cause:#
14 0arlier .et"ods used for integrating sub assembl# operations of floor and sub frame were done b# placing two clamps
diagnol towards eac" end6 more o)er welding parameters taken into consideration were also not as per t"e specified
standards&
Corre!ti*e + Pre*enti*e A!tion:#
14 2our D,E ,lamps facing eac" ot"er on bot" sides can be placed instead of two clamps6 welding parameters6 dul# c"ecked
and set as per specified standards will result in Aero gap between sub frame and runner tube&
24 2or implementing t"e abo)e procedure effecti)el# t"e s"op floor requires 7 more D,E clamps6 w"ic" can result in product
efficienc# in muc" limited time frame wit" qualit#&
34 'igorous $tructured training needs to be pro)ided to t"e man power concerned wit" t"e respecti)e department for
increasing producti)it#&
>"# 1?
*ifferences in Process C >elding @If/ If
<ot4
>"# 2?
In adequate material @tools/ fi-tures /
clamps etc4 @If / If <ot4
In pursuant of t"e abo)e root cause and correcti)e / pre)enti)e action6 we "a)e implemented t"e abo)e mentioned
Procedures/met"odolog# and eliminated t"e gap between sub frame and runner tube&
.aterial pertaining to .$ $quare tube was )isuall# tested for obtaining t"e desired results i&e Aero gap&


Than, &ou
Summary