ASSIGNMENT NO.

ARIA – VEHICLE IMPROVEMENT PROJECT

(BIW IMPROVMENTS)

OBJECTIVES

- TO IMPROVE PIST PERCENTAGE

- REDUCE DEMERITS

IMPORTANCE OF THE PROJECT:

• Low PIST percentage means poor quality of vehicle

• PIST symbolizes accuracy of manufacturing of the vehicle
• Low PIST percentage leads to problems in assembly of various
parts on body.
• Thus a good PIST percentage value is very important for good
Quality and smooth production of the vehicle.
INTRODUCTION

PIST : PIST stands for “points In specified tolerance” .

- It defines the error in position of the points beyond a
specified tolerance limit.
- Position of the points are measured using CMM
(coordinate measuring machine)

The LEGEND table for PIST is given below:

LEGEND range LEGEND Color

(Absolute)
Err >2.5 R (Red)

2.0 < Err <=2.5 A(Amber)

1.5 < Err <=2.0 Y(Yellow)

Err <=1.5 G(Green)

CALCULATION OF PIST PERCENTAGE:

To calculate PIST percentage coordinates of specified points are

measured using CMM. The relative error of these points in X,Y,Z
directions are then sorted into different legends or color bands.
The tolerance limits specified by the design is 1.5mm in all directions.
The percentage of points which are within the tolerance limits gives
the PIST value of a body in white

GRAPH OF PIST PERCENTAGE PREVIOUSLY RECORDED

100
86.63 82.99
90 79.2 80.24 78.01
80
70
60
50
40
30
20
10
0
PP57 SOP09 SOP15 SOP23 SOP40

CMM PIST% GRAPH

DEMERITS:
-DEMERITS shows the severity of the error .
- Demerits weightage for various error limits is as
shown .

DEMERITS RANGE DEMERIT

( Absolute ) (mm) WEIGHTAGE

ERR>4.5 20

3.5>ERR <=4.5 12

3.0<ERR<=3.5 8

2.5<ERR<3.0 4

2.0<ERR<=2.5 2

1.5<ERR<=2.0 1

ERR<=1.5 0
600
492
500
425 411
400
291
300
221
200

100

0
PP57 SOP09 SOP15 SOP23 SOP40

CMM DEMERIT GRAPH

MEASUREMENTR USING CMMCoordinate Measuring
Machine (CMM)

A coordinate measuring machine (CMM) is a device for measuring

the physical geometrical characteristics of an object. This machine
may be manually controlled by an operator or it may be computer
controlled. Measurements are defined by a probe attached to the third
moving axis of this machine. Probes may be mechanical, optical,
laser, or white light, among others

Uses

They are often used for:

• Dimensional measurement
• Profile measurement
• Angularity or orientation measurement
• Depth mapping
• Digitizing or imaging
• Shaft measurement

Features

They are offered with features like:

• Crash protection
• Offline programming
• Reverse engineering
• Shop floor suitability
• SPC software and temperature compensation.
• CAD Model import capability
• Compliance with the DMIS standard
• I++ controller compatibility
STEPS TAKEN FOR PIST &DEMERIT
IMPROVEMENT

• Studied the direction of three axes with respect to the

body. The X-axis is along the length of the body. The Y-
axis is along the width of the body and the Z-axis in the
vertical direction symbolizing height.
• Found out the origin of the three axes. The origin lies on
the front at the centre of the axle with X-axis dividing the
body in two equal halves i.e LH side and RH side while
Y-axis passes through the centre of the front axle.
• Found out the positions of various points considered for
PIST measurement using the reference of the axes and
previously recorded Data.
• Found out the points having maximum error with the
help of previous reports.
• Found out the possible causes of the errors by intensive
brainstorming.
• Studied the fixtures concerning the points under
consideration.
• Calculated the change to be made in the fixture also
considering the effect of the change on the neighboring
points on the same fixtures.
• Made respective changes to the fixtures by adding shims
with the help PE department engineer.
POINTS CONSIDERED AND CHANGES MADE:

1-Lock mtg slot on hood latch platform

Error: -4.9 on RH side in x direction.

Action taken: change made to the fixture shims of

appropriate dimension added.
One 1mm and 2mm shim added thus reducing the error.

2-plp hole on hood latch platform

Error:-4.8 on LH side in x direction

-3.8 on RH side in x direction

Action taken: change made to the fixture shims of

appropriate dimension added.
One 1mm and 2mm shim added thus reducing the error.

3-head lamp mtg hole on hood latch platform

Error:-4.9 on LH side in x direction

Action taken: change made to the fixture shims of

appropriate dimension added.
One 1mm and 2mm shim added thus reducing the error.

4-position of body mtg no4 at bottom

Error:-3.4 on LH side in z direction

Action taken : part manufactured by supplier (Sharda

industry). Visited suppliers workshop. Suggested modification
in fixture

5-at bottom rear door hinge mtg hole at front

Error: 2.8 on RH side in y direction

Action taken: no action taken. Uncontrollable process error.

Part obtained from the supplier. Punched hole.

POINTS CONSIDERED

POINT 04- LOCK MTG SLOT ON HOOD LATCH PLATFORM.

POINT 05-PLP HOLE ON HOOD LATCH PLATFORM.

POINT 06-HEAD LAMP MTG HOLE ON HOOD LATCH

PLATFORM
POINT 35B-POSITION OF BODY MTG N0.4 AT BOTTOM

POINT 63-AT BOTTOM REAR DOR HINGE MTG.HOLE AT

REAR
RESULTS:-

• Problem related to assembly of hood latch solved

• Better PIST percentage obtained
• Reduction in DEMERITS
• Thus improvement in quality