Storm QCC: Welcomes You All For Our Second Project Presentation

QC STORY
STORM QCC
WELCOMES YOU ALL

FOR OUR SECOND PROJECT
PRESENTATION DEPT CODE PRO. CODE PAGE NO
STORM
238 02 1
QCC
QC STORY INTRODUCTION
DEPT CODE PRO. CODE PAGE NO

STORM
238 02 2
QCC
Milestones
• 1968 Started as captive unit with aluminium
Gravity Die castings - GDC
• 1983 Started manufacturing aluminium Pressure
Die castings -PDC.
• 1987 Awarded for best industrial

relations by Government of Tamilnadu.
•1993 Started Die design using CAD
•2000 Certified for QS - 9000.
•2000 Installed alloying plant
•2000 Global supply commenced.
•2001 Best supplier award from Hyundai
Motor India limited.
•2001 Started collaborative product.
development with MNC customer. DEPT CODE PRO. CODE PAGE NO
STORM
238 02 3
QCC
Sundaram Clayton QCC Projects trend - DCD
100% Participation
700
581
600
482 100 100 100 100 100 100 100
100
500
387 80
No of projects
400
% of participation
303 75
65
300 241
196 50
200 148
62 84 95 99
106
82
60 42 48 45
236 24 22 24
100 25
0
95-96 96-97 97-98 98-99 99-00 00-01 2001- 2002- 2003- 2004- '05-Jan 0
02 03 04 2005 06 97-98 98-99 99-00 00-01 2001-02 2002-03 2003-04 2004- 2005-
2005 2006
Year Year

STORM
238 02 4
QCC
SCL - Die Casting Division Customers
Domestic Export
 TVS Motor Company  Cummins Group
 Sundaram-Clayton  Cummins , USA
(Brakes Division)  Komatsu Cummins - Japan
 Hyundai Motors  Fleetguard, USA
 Ford  Holset, USA
 Visteon  Ford - Brazil, Mexico and
 Honda South Africa
 Volvo Under negotiation
 Tata Cummins  Volvo, Sweden
 Tata Holset  Mack, USA
 Sona Koyo Steering  Renault, USA

Systems
STORM
238 02 5
QCC
STORM QUALITY CIRCLE

STARTED MONTH& YEAR : DECEMBER - 2004
NATURE OF WORKING AREA : PLANT MAINTENANCE
LEADER : D.SAMUEL RAJAN

MEMBERS : S.VIJAYAN
: S.SHANMUGAPRABU
: N.SUBRAMANIAN
: S.SILAMBARASAN
: S.SHAHUL HAMEED
FACILITATOR : P.NETHAJI.
MEETING DAY :EVERY WEDNESDAY AT

3.45 PM TO 4.45 PM
STORM
238 02 6
QCC
QC STORY 1.0 PROBLEM
HIGH BREAKDOWN IN FILTER

MODULE CELL
(196Hrs & 32 Freq. )
Apr’05 - Jun’05
CELLWISE BD HOURS
196
200
150
BD Hrs
100 82
62
51
50 36 31
25 18 12 8
4
0
Ford oilpan
Honda Case
Head FF
CLOC
MY 4.5
Lub module
module
Honda
Visteon
Gear Hsg
Filter
ISX
Chain

STORM Cell
238 02 7
QCC
QC STORY 1.2 IMPORTANCE OF PROBLEM
• Machine breakdown leads to delivery failure
• Delivery failure leads to Business loss
• TPM calls zero breakdown.
• The Breakdown of a machine affects the entire cell output.
10700 60
10680
CELL OUTPUT
10660 56
BD HOURS
10640
Cell
10620 52 output
10600
10580 48
10560 M/C
10540 44 Break
10520 down
10500 40
Apr'05 May'05 Jun'05 MONTH
STORM
238 02 8
QCC
QC STORY OBJECTIVES
Policy Deployment Objectives-X-matrix(DCD Machining Cell):

Die Casting Division-PMD Machining
4.1 Implementation of TPM company wide
3.3 Build competenece in casting process
3.2 Strengthen NPD process
3.1 Standaardise learning through SOP's guibelines and project PDCA
2.3 Implement poke Yokes
2.2 Revisit die and process design
2.1Establish process controls and adhere(measure:no of out of control processes)
1.6Improve capital and employee productivity by re-engineering,low cost automation and
outsourcing(measure:sales/employee and sales of GFA)
1.5 Implement waste elimination project-yield,Melting,Energy,consumables
1.4 Alternate sourcing
1.3 Maximise export benefits and FTA buying for aluminium purchase(Measure
1.2 Pamp-up new products on time (meausure
1.1 Retain market share with existing customers (measure:
100%
100%
3 1 .4
2 5 .2
95%
75%
1 A 4 D a ily M o n it o rin g o f ' B ' & ' C ' ra n k M5/0c %B / d 9 5 %
75%
336
100
6 .2
0 .5
TO
TO
10
21
37
10
GUIDELINES
2
FROM
FROM
PRESIDENT
ppm 1800
2 6 .5
2 5 .8
80%
1 A 2 D a ily P D C A o f ra n k ' A ' m a c h in e s 8 0 %
20%
10%
80%
256
0 .7
1 .9
1 .4
24
28
I n c r e a s e n e w p r o d u c t s a l e Rs sa nc dr 8
Rs cr
Rs cr
1 A 3 M a in t a in S t o c k o f c rit ic a l s p a re s
i m p r o v e n e w p r o d u c t q u a l i ty%
%
%
%
%
%
1 A 5 M a in t a in e s s e n t ia l s p a re s t o c k
1 A 1 In c r e a s e N o . o f P M c h e c k s
1 A 5 S t e n g t h e n w e e k ly P M
In c re a s e s a les a n d
OBJECTIVE
R e d u c e r e j e c ti o n s
ACTION PLAN
C u s to m e r e n d
P r o fi ta b i l i ty
M a c h in in g
C a s ti n g
Head-DCD PMD
P r o fi t
Machining
OBJECTIVES
FROM TO
3
1A1 Reduce overall M/c B/D %(machine Wise) 0.60 0.30

1C1 Reduce overall M/c B/D Frequency 290 140
1D1 Reduce repair and maintenance cost(lakhs) 177.23 150
F :\B P N \0 0 1 \B P N r e v . 0 d t 1 9 .0 3 .2 0 0 5
1E1 Redcuce MTTR 4.5hrs 4hrs

1F1 Reduce MTBF 80days 60days
1G1 Reduce Enegy consumption 3% 8%
R E S P O N S IB IL IT Y
1 Marketing
MATRIX OF POLICY FOR 2005-2006 2 Operations - DCD
3 Operations - Machining
DIRECTED BY : President 4 Purchase DEPT CODE PRO. CODE PAGE NO
STORM
5 Quality assurance
TO : Head-DCD PMD M/ing 6 Engineering
238 02 9
QCC To Reduce BD% from 0.60 to 0.30
TO QC STORY OBJECTIVES
TO
GUIDELINES
FROM
FROM
PRESIDENT
OBJECTIVE ACTION PLAN
Head-DCD PMD
Machining
OBJECTIVES
FROM TO
1A1 Reduce overall M/c B/D %(machine Wise) 0.60 0.30
1B1 Reduce overall M/c B/D %(Cell Wise)
1C1 Reduce overall M/c B/D Frequency 290 140
1D1 Reduce repair and maintenance cost(lakhs) 177.23 150
1E1 Redcuce MTTR 4.5hrs 4hrs
1F1 Reduce MTBF 80days 60days
1G1 Reduce Enegy consumption 3% 8%
STORM
238 02 10
QCC
QC STORY 1.3 Theme and Target
TARGET
Break down percentage for Filter module Cell
2
1.6 1.58 1.53
Less than 0.25% by the

1 month of Aug’05
B/D %
0.25
0
Apr'05 May'05 Jun'05 Jul'05 Aug'05
Month
STORM
238 02 11
QCC
QC STORY BACKGROUND
CUSTOMER : FLEET GUARD
PRODUCT NAME : FUEL FILTER

HOUSING
PART NUMBER : 393588800
APPLICATION : FILTER ASSEMBLY
DELIVERY : FULLY MACHINED
MATERIAL : ALUMINIUM - ADC12
COMPONENT COST : $ 15.35

:
CASTING TYPE : PRESSURE DIE CASTING

STORM
238 02 12
QCC
QC STORY 1.4 SCHEDULE FOR IMPROVEMENT
GANTT CHART
WEEK NO
ACTIVITIES RESP 14 15 16 17 18 19 20 21 22 23 24 25
DATA COLLECTION TEAM
PROBLEM SELECTION TEAM
ANALYSIS TEAM
SOLUTION SELECTION TEAM
IMPLEMENTATION TEAM
OBSERVATION TEAM
STANDARDISATION TEAM

STORM PLAN 238 02 13
QCC
QC STORY 2.0 OBSERVATION – COLLECT &ANALYSE DATA
DATA COLLECTION FOR CELL WISE B/D FREQ.

& HOURS (FROM APR‘05 - JUN‘05)
Hour s
Cell Hours Frequency
Visteon 7.24 3
196.33
Gear Housing 17.76 6
200
Filter Module 196.33 32
Honda Case Chain 25.47 6 10 0
cloc 35.57 8
0
Lube Module 50.79 14
Head FF 61.89 5
Case chain
Honda Case
Oil pan
ISX Fwh
Visteon
Oil pan
Module
MY 4.5
Honda
Housing
Head FF
Module
Honda Oilpan 31 4
Cloc
Ford
Honda
Filter
Chain
Lub
Gear
Ford Oilpan 4.17 1
Honda Casechain 23 6
Frequen cy
MY 4.5-Holset 12 5
ISX-Flywheel Hsg 82 17
Frequency 40
32
20
Case chain
Honda Case
Oil pan
ISX Fwh
Visteon
Oil pan
Module
MY 4.5
Honda
Housing
Head FF
Module
Cloc
Ford
Honda
Filter
Chain
Lub
Gear

STORM
238 02 14
QCC
PARETO ANALYSIS FOR FILTER MODULE

BREAK DOWN DETAILS
Sno Machine Description B/D HRS %

%
1 089407 WINNER XL 1.83 0.93 240 120
220
2 033501 ACE LT 20C 9.5 4.84 200 93.25 98.09 99.02
100 100 100
88.19
3 033502 ACE LT 20C 0 0 180
160
162
80
4 033801 LT-20CLASSIC 1.75 0.9 140

120
82.5
60
5 085839 SPM 162 82.5 100

80 40
6 089505 AMS MCV400 11.25 5.69 60

40 20
7 089506 AMS MCV400 10 5.06 20 11.17 10 9.5 1.83 1.75 0

0 0
Total 196.33 100 85839 89505 89506 33501 89407 33801 33502
M/c
B/D Hrs

STORM
238 02 15
QCC
PARETO ANALYSIS FOR FILTER MODULE

BREAK DOWN DETAILS
Sno Machine Description B/D Freq. % %

1 089407 WINNER XL 2 6.25 40 120
2 033501 ACE LT 20C 1 3.12 36

32 93.75 96.87
100 100
100
87.5
3 033502 ACE LT 20C 0 0 28 24
81.25
80
4 033801 LT-20CLASSIC 2 6.25 24

20
75
60
5 085839 SPM 24 75 16 40
12
6 089505 AMS MCV400 1 3.12 8 20
2 2 2
7 089506 AMS MCV400 2 6.25 4 1 1 0
0 0
Total 32 100 85839 89407 33801 89506 33501 89505 33502
M/c
B/D Freq.

STORM
238 02 16
QCC
QC STORY
DRILLING SPM - 085839

Clutch unit
Cylinder
Spindle
unit

STORM
238 02 17
QCC
Breakdown Hours & Breakdown Frequency

Of 085839 SPM For the month of Apr’ 05-Jun’05
BD HOURS BD FREQUENCY
80
12
58 10
60 53 51
8 8
BD hours
BD Freq.
40 6
20 4
0
0

STORM
238 02 18
QCC
QC STORY PROCESS DETAILS
FLOW CHART FOR FILTER MODULE CELL

CASTING FROM
FOUNDRY
ACE LATHE LT 20C ACE LATHE LT 20C

033801 033502
AMS MCV 400 AMS MCV 400

089506 ACE LATHE LT 20C
089505
033501
DEBURRING
AMS WINNER DRILLINGSPM
089407
FINAL INSPECTION&
LEAK TESTING WASHING
PACKING

STORM
238 02 19
QCC
QC STORY 2.0 OBSERVATION-COLLECT ANALYSE DATA
PARETO ANALYSIS ON BREAKDOWN DETAILS OF DRILLING

SPM (APR’05-JUN’05)
SL.NO. PROBLEMS B/D HRS FREQ
1 Spindle unit not moving down 155 17
2 Coolant not coming 2.5 2
3 Component not clamped 1.5 1
4 Counter weight chain cut 2.5 3
5 Air leak 0.5 1
TOTAL 162 24
B/D HOURS 100 100 B/D FREQUENCY

320 99.6 100 100
99 91.66 95.67
98.6 20
17 83.33 80
240 98
15 70.83
97.1 97 60
155
160 96 10
95.6 40
95
80 5 3 20
94 2
1 1
2.5 2.5 1.5 0.5
0 93 0 0
Counter weight
Spindle unit not
Spindle unit not

Component not
Counter weight
Component not
moving down
moving down
Coolant not
Coolant not
Air Leak
Air Leak
chain cut
chain cut
clamped
clamped
coming
coming

STORM
238 02 20
QCC
QC STORY
SPM - CLUTCH ENGAGING MECHANISM:
Spindle Motor
Worm wheel &
Worm shaft The Motor drive is transmitted
Drive to the worm wheel and to the
Driven
worm Shaft.
Compressed Air
The drive from the worm shaft is
Transmitted to the clutch plate
drive shaft.
Pinion
Lock Pin
Spindle unit

STORM
238 02 21
QCC
QC STORY
Spindle Motor The output from the valve actuates the cylinder
Worm wheel &
And the driven shaft which is connected to the
Worm shaft Piston got engaged to the clutch plate.
Driver
Driven The pinion which is connected to the driven shaft
Will rotates and the rack will starts to move down.
Compressed Air
Pinion
Lock Pin
Spindle unit

STORM
238 02 22
QCC
QC STORY

After clutch plate gets engaged the air
Spindle Motor Worm wheel &
supply to the cylinder will cut off
Worm shaft
Then the single acting cylinder piston
Driver will retracts to its original position
Driven
Mean while the spring loaded lock pin

will move up and locks the clutch plate
in engaging condition.
Compressed Air
Pinion
Lock Pin
Spindle unit

STORM
238 02 23
QCC
QC STORY
WHY SPINDLE NOT MOVING UP/DOWN

FREQUENTLY?

STORM
238 02 24
QCC
QC STORY BRAIN STORMING
BRAIN STORMING
WHY SPINDLE UNIT NOT MOVING UP/DOWN?
• Pneumatic Valve struck up • Component not clamped
• Cylinder struck up • Cylinder seal failed
• Counter weight chain cut • Clutch pin broken
• Solenoid coil failure • Pin spring broken
• Wire cut • Spring weakened
• Limit switch struck up • Spindle motor winding failure
• Pressure switch failure • Loose connection
• Gear engagement failure • Pinion gear broken 0
• Handle locking pin broken • Component wrong loading
• Clamp not working • Low Voltage
• Motor not running • Clutch not engaging
• Proper feed not coming • Air Pressure low
• Counter weight misaligned • FRL unit failure
• Pneumatic Push button
failure
• Pneumatic hose cut
• Counter weight loaded
• Clutch pin got bend DEPT CODE PRO. CODE PAGE NO
STORM
238 02 25
QCC
QC STORY 3.1 CAUSAL ANALYSIS
Man Pneumatic pressure. Machine Gear not Lock pin

Hose cut engaging broken
Air Regulator failure
pressure Gear tooth Clutch unit
low Wrong Pr. Worn out Not engaging
Valve failure
setting Cylinder failure Drive not
Push button failure transmitting
Supply problem Spindle
Component Motor not
Loose connection Not clamped Shaft worn out
running
Wire cut Supply problem WHY SPINDLE
UNIT NOT
Due to MOVING
Hose burst
Poor quality pin age UP/DOWN?
Hose Hose
Lock pin broken Weak stretched
Cont. pressure in
hose
Air
leakage
Frequent wear and tear Valve failure
Seal damage
Method Material

STORM
238 02 26
QCC
QC STORY 3.2 VALIDATION AND ROOT CAUSE IDENTIFICATION
LOOSE CONNECTION CHECK POINTS
CONNECTION TIGHTNESS
SL.NO. LOCATION OK NOT OK
1 IN ELECTRICAL PANEL
2 PLUG IN BOX
3 ACCESSORIES TIGHTING
OK
NOT OK

STORM
238 02 27
QCC
Low Pneumatic Machine Gear not Lock pin

pressure. Hose cut engaging broken
Regulator failure
Gear teeth Clutch unit
Worn out failure
Valve failure
Cylinder failure Clutch not engaging
Voltage high
Voltage variation Drive not
transmitting
Motor not Spindle
running Shaft worn out
Loose connection
voltage Voltage low WHY SPINDLE
UNIT NOT
MOVING
UP/DOWN?
Sl.noWHAT WHERE WHY HOW VALIDATION

1 pneumatic pressure Pressure gauge Regulator failure Checked regulator function ok In significant
2 voltage Control Panel Voltage variation Checked voltage (420 V) In significant
3 Lock pin broken Clutch unit Not withstanding load Checked pin broken Significant
4 Clutch not engaging Clutch unit No force to clutch engageChecked clutch not engaged Significant

STORM
238 02 28
QCC
Man
Air
pressure
low Wrong Pr. Component loaded Component not clamped
setting Wire cut
Motor not Spindle struck
running
Loose connection
Supply problem WHY SPINDLE
UNIT NOT
MOVING
UP/DOWN?
WHAT WHERE WHY HOW VALIDATION

Air pressure low pressure gauge No correct setting(6 bar) Checked setting ok In significant
Loose connection panel board Not tightened Checked tightnes ok In significant
Component not clamped In fixture Lack of knowledge Checked not clamped Significant

STORM
238 02 29
QCC
WHY SPINDLE
UNIT NOT
MOVING
Due to Hose burst
Poor quality pin age UP/DOWN?
Hose
Hose stretched
Lock pin broken Cont. pressure in hose
Weak
Air
leakage
Frequent wear and tear Valve failure
Seal damage
Material
Sl. No. What Where Why How Validation

1 Lock pin broken clutch unit Poor quality material
Checked material ok In significant
2 Hose Cut Supply line due to aging Checked condition ok In significant

STORM
238 02 30
QCC
QC STORY 4.1 DEVELOPMENT OF SOLUTION
Validation of root cause 1:-

Lock Pin Broken
Driver
WHY? Driven
Compressed
Not able to with stand load Air
WHY? Pinion
Uneven load acting on pin Lock Pin
WHY?
No opposing force to clutch
WHY? Spindle unit
Design Constraint
SOLUTION 1 SOLUTION 3
Provide hydraulic Provide pneumatic Modify pneumatic

cylinder for spindle cylinder for spindle circuit
up/down up/down DEPT CODE PRO. CODE PAGE NO
STORM SOLUTION 2 238 02 31
QCC

Clutch not engaging
WHY?
Insufficient force to engage
WHY?
The contact surface between pin & clutch plate is less
WHY?
Design constraint
SOLUTION 4 SOLUTION 6
Provide additional Modify Pneumatic Modify Clutch

pin to lock clutch circuit design

SOLUTION 5
STORM
238 02 32
QCC

Component not clamped in auto cycle
WHY?
Operator not clamped the component
WHY?
Lack of knowledge
Training to be given Clamping to be done in Clamp condition to

to operator auto cycle be interlocked in M/c
SOLUTION 7 SOLUTION 8 SOLUTION 9

STORM
238 02 33
QCC
Solution 1:
Providing Hydraulic Cylinder For Spindle up/down
Sno Solution Action Advantages Disadvantages

1.Production stop
Providing Hydraulic Eliminated
while modifying.
1 hydraulic cylinder to be lock pin &
2.Design cost
cylinder fixed in M/C Clutch unit.
high.
HYDRAULIC CYLINDER
Hence Solution Dropped

STORM
238 02 34
QCC
Solution :2
Providing Pneumatic Cylinder For Spindle up/down
1.Production stop
Providing Pneumatic Eliminated
while modifying.
1 pneumatic cylinder to be Lockpin &
2.Design cost
cylinder fixed in M/C Clutch unit.
high.
PNEUMATIC CYLINDER

FEED CYLINDER

STORM
238 02 35
QCC
Solution 3: Modifying the Pneumatic circuit

1.Lock pin will
be eliminated.
Clucth to be fully 2.Design cost
Modify the
1 engaged by low. Nil
pneumatic circuit
pneumatic 3.Clutch will
be positively
engaged.
Hence Solution can be taken

for implementation DEPT CODE PRO. CODE PAGE NO
STORM
238 02 36
QCC
Solution 4: Provide additional pin to lock clutch

Additional lock
Additional lock 1.Uneven load 1.Difficult to fix
pin to be fixed in
1 pin to be can be additional lockpin
the clutch unit in
introduced balanced. in the clutch unit
M/C
Additional lock pin

To be fixed

Existing Lock DEPT CODE PRO. CODE PAGE NO
STORM Pin Location
238 02 37
QCC

1.Lock pin will
be eliminated.
Clucth to be fully 2.Design cost
Modify the
1 engaged by low. Nil
pneumatic circuit
pneumatic 3.Clutch will
be positively
engaged.

for implementation DEPT CODE PRO. CODE PAGE NO
STORM
238 02 38
QCC
Solution 6:
MODIFYING CLUTCH DESIGN

1.Production stop
Electro magnetic Eliminated
Modifying the while modifying.
1 clutch to be lock pin &
clutch design 2.Design cost
introduced. Clutch unit.
high.

STORM
238 02 39
QCC
Solution 7:
Training to be given to operator
Operator
Training to be Training given to Possibilty of
1 mistake can
given to operator. operator making mistake.
be eliminated.

for implementation
STORM
238 02 40
QCC
Solution 8:
Clamping to be done in auto cycle
1.Design cost
Clamping to be Logic Component
high
1 done in auto modification to clamped
2.Cycle may run
cycle. be done. automatically
with out clamp.

STORM
238 02 41
QCC
Solution 9:
Clamping condition to be interlocked in
machine
Clamping Cycle will not
Clamping
interlock run without
1 contion to be Nil.
introduced in component
interlocked
machine. clamping.

for implementation
STORM
238 02 42
QCC
QC STORY 4.2 Action plan
ACTION PLAN CHART FOR SOLUTION
IMPLEMENTATION
Sl. No. Action(What) When Who How
1 Analyse the Pneumatic sequence Week 19 Qc members By observation
2 Modify the pneumatic circuit Week 19 Qc members Maintenance department
3 Connection with Machine Week 21 Qc members In the Clucth
4 Check for proper operation Week 22 Qc members Monitoring the machine function
5 Observation Week 23 Qc members Breakdown monitoring

STORM
238 02 43
QCC
QC STORY
Before QCC FEED PNEUMATIC CIRCUIT DIAGRAM

CYLINDER
CLAMPING CYLINDER
DECLAMP
CYCLE START
TIMER
CYCLE START

STORM
238 02 44
P QCC
QC STORY 5.2 BENEFITS
Before QCC
ELECTRICAL DIAGRAM
R
Y
B
PE
STOP
MPCB
START K1
CONTACTOR
K1 (230vAC 50hz)
Motor
3 phase N

Spindle
STORM motor 238 02 45
QCC
Before QCC: SPM - CLUTCH ENGAGING MECHANISM:
Driver
Driven
Compressed Air
Pinion
Lock Pin
Spindle unit
STORM
238 02 46
QCC
Driver
Driven
Compressed Air
Pinion
Lock Pin
Spindle unit
STORM
238 02 47
QCC
Driver
Driven
Compressed Air
Pinion
Lock Pin
Spindle unit
STORM
238 02 48
QCC
Driver
Driven
Compressed Air
Pinion
Lock Pin
Spindle unit
STORM
238 02 49
QCC
QC STORY
After QCC: FEED CYLINDER L2

CLAMPING CYLINDER
Pressure
Switch
Z14 Z12
3/2 WAY 5/2 WAY VALVE

VALVE P P
CYCLE START
CYCLE START
(L2) LIMIT SWITCH

DECLAMP
P
STORM
QCC
MODIFIED CIRCUIT DIAGRAM 238 02 50
After QCC: SPM - CLUTCH ENGAGING MECHANISM:
Driver
Driven
Compressed Air
Pinion
Spindle unit
STORM
238 02 51
QCC
After QCC: SPM - CLUTCH ENGAGING MECHANISM:
Driver
Driven
Compressed Air
Pinion
Spindle unit
STORM
238 02 52
QCC
QC STORY 5.1 CHECK
OBSERVATION
S.No 10 11 12 13 14 15 16
8.00 am
4.00 pm
WEEK 21
11.00 pm
S.No 17 18 19 20 21 22 23
8.00 am
WEEK 22
4.00 pm
11.00 pm
S.No 23 24 25 26 27 28 29
8.00 am
WEEK 23
4.00 pm
11.00 pm
No Break down
STORM
Break down 238 02 53
QCC
QC STORY
B/D HOURS OF SPM-085839

100 100
320 99.6
99
98.6
240 98
97.1 97
155
160 96
95.6
95
80
94
2.5 2.5 1.5 0.5
0 93
Spindle unit not moving down
Counter weight chain cut
Component not clamped

THUS 95.6% OF
Coolant not coming
Air Leak
THE PROBLEM
SOLVED

STORM
238 02 54
QCC
QC STORY
We Decided to Kill the Other

Phenomenon In SPM
Counter measure

STORM
238 02 55
QCC
QC STORY
WE DECIDED TO SOLVE THE REMAINING

4.4% OF
99.6
100
THE
100
PROBLEM.
320
99
98.6
240 98
97.1 97
155
160 96
95.6
95
80
94
2.5 2.5 1.5 0.5
0 93
Coolant not
Spindle motor
weight chain
getting up/down
Spindle unit not
Air Leak
not rotating
coming
Counter
Remaining Problems : cut
1. Spindle coolant not coming.

2. Component not clamping.
3. Counter weight chain cut.
4. Air leak from the hose.
STORM
238 02 56
QCC
Phenomenon1:Coolant not coming
Coolant not coming

WHY?
Burr blocked in the pipe line
WHY?
Coolant coming along with burr
WHY?
Filter not provided
CM ‘Y’ Strainer provided in the Line

STORM
238 02 57
QCC
QC STORY
COUNTER MEASURE TAKEN FOR PHENOMENON: 1
BEFORE AFTER
“Y”
STRAINER

STORM
238 02 58
QCC
Phenomenon2:Component not clamping
Component not clamped

WHY?
Air Leak from the cylinder
WHY?
Cylinder seal worn out
WHY?
Due to aging
CM Replaced the seals

STORM
238 02 59
QCC
Phenomenon3 : Counterweight chain cut
Chain cut
WHY?
Chain not able to withstand load
WHY?
Ineffectiveness in weight resting
WHY?
Low tension spring
WHY?
design constraint
CM DEPT CODE PRO. CODE PAGE NO
STORM Spring tension to be increased 238 02 60
QCC
QC STORY
COUNTER MEASURE TAKEN FOR PHENOMENON: 3

BEFORE Counter weight AFTER
High tension
Low tension spring
spring

STORM
238 02 61
QCC
Phenomenon 4:Air leak from hose
Air leak from hose

WHY?
Air hose burst
WHY?
Not able to withstand pressure
WHY?
Due to aging
CM Replaced the Hose

STORM
238 02 62
QCC
QC STORY 5.1 CHECK
ELIMINATED BREAKDOWN FROM 162 Hrs TO ZERO

TILL NOW
80
BEFORE QCC AFTER QCC
60 58
53
51
BD HRS
40
20
0 0 0 0 0 0 0 0 0 0 0 0 0

STORM BREAK DOWN HRS
238 02 63
QCC
QC STORY 5.1 CHECK
REVISED GANTT CHART

WEEK NO
ACTIVITIES RESP 14 15 16 17 18 19 20 21 22 23 24 25
DATA COLLECTION TEAM
PROBLEM SELECTION TEAM
ANALYSIS TEAM
SOLUTION SELECTION TEAM
IMPLEMENTATION TEAM
OBSERVATION TEAM
STANDARDISATION TEAM
PLAN DEPT CODE PRO. CODE PAGE NO

STORM
ACTUAL 238 02 64
QCC
QC STORY 5.1 CHECK
Comparison
S.No Before QCC After QCC
1 Clutch Not user friendly Clutch User friendly
2 Lock pin used to engage Pneumatic pressure
clutch used to engage clutch
3 Pneumatic Timer used Timer eliminated
4 Spares not available in Availibility of spares are
market easy
5 Complication of electrical & Simple electrical &
pneumatic circuit pneumatic circuit
No interlock for component Interlock provided for
6 clamp component clamp
Difficult to set the drill Drill depth can be
7 depth adjusted easily.
STORM
238 02 65
QCC
TANGIBLE BENEFITS
 SPM Spindle unit Up/Down breakdown frequency reduced
from 24 to 0.
Cost of drill bit:Rs.1400/-

Cost of three Broken drill bits:3*1400=Rs.4200
Cost of clutch lock pin:Rs.400/-

Total no. of times Lock pin broken:3 times
Total cost of pin:3*400=Rs.1200/-
Cost of Pneumatic timer is:Rs.4822/-
Total cost saving of this project:4200+1200+4822=Rs.10622/-
Cost of Pressure switch used in this project:Rs.600/-
Net saving:Rs.10622-600=Rs.10022/- DEPT CODE PRO. CODE PAGE NO

STORM
238 02 66
QCC
INTANGIBLE BENEFITS
• Machine Safety Improved.
• Customer Satisfaction Achieved.
• Machine availability Increased.
• Machine Malfunction (Due To up/down) Eliminated.
• Machine accident eliminated.
• Lock pin eliminated.
• Pneumatic timer eliminated.
• Component clamp interlock introduced.

STORM
238 02 67
QCC
QC STORY 6.0 Standardization
Standardization
Standardization::
Sl no Activity Necessity Where Resp Method
TS 16949 PMD PN Entered the modification details
requirements in history cards & also a copy
in the Machine code folder
1 DOCUMENTATION
For Reducing PMD Team Modified the pneumatic circuit

2 MODIFICATION
Break down
Entered the Check points in PM

UPDATION IN PM For Reducing PMD PN check list.
3
CHECKLIST Break down

STORM
238 02 68
QCC
QC STORY 6.0 Standardization
5.1 CHECK
PM Master Check List

2 Check the condition of MPCB Half yearly
3 check tightness for all proximity&sensor locknut Half yearly
4 Check pilot operated coolant switching on valve for its normal working condition. Half yearly
5 Fill Grease in Spindle & Multi gear box Half yearly
6 Clean burr in coolant line, filter &coolant tank Monthly
7 Drain moisture in Filter bowel & clean Monthly
8 Tighten all Coolant pipe fittings Monthly
9 Tighten all hydraulic line fittings Monthly
10 Remove the drained oil from the Slide Monthly
11 Check the auto/manual switch condition Quarterly
12 Check condition of terminal connector for hyd.&coolant Quarterly
13 Tight all the solenoid coil connections Quarterly
14 Tight the wire connections in the P.B Quarterly
15 Tight the PLC unit cable connection Quarterly
16 Check the lever type limitswitch for cyclestart for its normal working condition. Quarterly
17 Check main Hydraulic pressure for 4-5 kgf/cm2 Quarterly
18 Route all hoses clearly Quarterly
19 Check the condition of the pneumatic hoses Quarterly
20 Check the condition of the pneumatic cylinder seal condition Quarterly
21 Check the condition of the counetr weight chain Quarterly
22 Clean the lubrication unit filter Quarterly
23 Replace the damaged lub oil hoses Quarterly
Sl.No Check Points Frequency

STORM
238 02 69
QCC
QC STORY 6.1 POKA YOKE
Prevent error Shut down

Detect error Control
Alarm
DESCRIPTION OF THE PROCESS : Ensure component clamping in
Filter module SPM
Before improvement L1 L2 L3 After improvement
L1 L2 L3
Contactor
STOP START Contactor
OLR Pressure
Switch OLR
M
M
N Clamp Signal
Without clamping cycle will run Without clamping cycle will not run N

STORM
238 02 70
QCC
QC STORY QC Tools
TOOLS USED
Jan'98 Feb'98 Mar'98 Total
Tested 826 278 216 494
Rejection 80 24 24 48
Check sheet % Rejection 9.7 8.6 11.1
100 100
100
96
80 80
60
60 60
Pareto Diagram
40 30 40
20 10 20
4
0 0
Excess Standout Off Leak Less Output
Cause & Effect Diagram QC tools

800
600
Graph & Control Chart

400
200
0
92-93 93-94 94-95 95-96 96-97 97-98 98-99
Histogram
1.7
1.5
1.3
1.1
OTHER TECHNICS USED:
Scatter Diagram
0.9
0.7
36.1 36.2 36.3 36.4 36.5 36.6 36.7 36.8 36.9 37 37.1 37.2 37.3
12
10
11.1
1. FLOW CHART
2. KAIZEN SHEET
8 8.6
6 6.8
2 ShiftA Shift
Stratification
0
Feb'98 A Mar'98
3. PHENOMENA MATRIX
4. POKA YOKE
STORM
238 02 71
QCC
QC STORY
Sundaram clayton limited Machine : 085839

DCD PMD Machining
Jipm- TPM KAIZEN SHEET Unit : DCD-Machining
Month : May ‘05
Ref : PMD/M/038
Kaizen Theme : To eliminate breakdown due to burr Target & Target Date: Provide a Y strainer in the
Blockage. Delivery Line.
Problem : Counter measure : Provide a Y strainer in the
Delivery Line.
Burr blocked in the coolant line Before Counter Benefits / Results after
Measure : Implementation :
Analysis : No burr blockage in the

Why? Coolant line.
Burr blocked in the coolant line
Why?
Burr entered in the coolant line
Why?
Burr carryover along with coolant
After Counter Measure :
Why? Scope & Plan for horizontal
No filter provided deployment :
Improvement: Provide a filter in the For all spm

Delivery line. machines
Root Cause : Weak design
Idea : Provide
a filter in the
delivery line DEPT CODE PRO. CODE PAGE NO
STORM
238 02 72
QCC
QC STORY
Sundaram clayton limited Machine : 085839

DCD PMD Machining
Jipm- TPM KAIZEN SHEET Unit : DCD-Machining
Month : May ‘05
Ref : PMD/M/038
Kaizen Theme : To eliminate Counter weight chain cut. Target & Target Date: Provide a Y strainer in the
Delivery Line.
Problem : Counter measure : Changed low to high tension spring
Counter weight chain cut Before Counter Benefits / Results after

Measure : Implementation :
Analysis : Counter weight chain cut eliminated

Why? Spring breakage avoided.
Chain cut
Why?
Chain not able to withstand load
Why?
Ineffectiveness in weight resting
Why? After Counter Measure :
Scope & Plan for horizontal
Low tension spring deployment :
Why?
design constraint
Improvement: Introduced high
tension spring
Root Cause : Design constraint
Idea : Introducing a high tension

spring DEPT CODE PRO. CODE PAGE NO
STORM
238 02 73
QCC
QC STORY 5.1 CHECK
Phenomenon Matrix
BREAK DOWN PHENOMENON MATRIX

Machine:085839
J u n' 0 5 J ul y ' 0 5 A ug ' 0 5 S e p '0 5

Root Caus
Kaize
e n Ide a/ Counte rAction
m e as ur
Cat.
e
W K6 W K7 W K8 W K9 W K10 W K11W K12 W K13 W K14 W K15 W K16 W K17 W K18 W K19W K2 0W K2 1W K2 2
Pneumatic engage timePneumatic

less circuit modif
CMied1 3 3 5 0 0 0 0 0 0 0 0 0 0 0 0 0
Burr entry Y-strainer provided

KAIZEN - - - - - - - C 1 0 0 0 0 0 0 0 0
w orn out Seal condition to be CM

checked
- in- PM - - - - - - C 0 0 0 0 0 0 0 0
Counter w eight chain cut

Resting spring changed
KAIZEN - - - - - - - - 3 0 0 0 0 0 0 0 0
Hose hardened Hose condition to beCM

checked
- in
- Pm - - - - - - C 0 0 0 C C 0
NO
Break Down
KAIZEN DEPT CODE PRO. CODE PAGE NO
C 0
Break Down 1
STORM
238 02 74
QCC
QC STORY 7.0 CONCLUSION
Conclusion
Conclusion::
Small change in design will leads to
Big change in machine availability.

STORM
238 02 75
QCC
QC STORY Next Project
OUR FUTURE PLAN
*REDUCE BREAKDOWN HARDINGE GROUP MACHINES.

STORM
238 02 76
QCC
QC STORY THANKS
THANK YOU

STORM
238 02 77
QCC
QC STORY
INFO ABOUT CLUTCH:
TO TRANSMIT MOTION WHEN NEEDED

DEPENDS ON LAW OF FRICTION
FRICTION HELPS TO TRANSMIT MOTION

STORM
238 02 78
QCC
QC STORY

STORM
238 02 79
QCC
QC STORY WELCOME
Sundaram Clayton Ltd

Die casting Division
STORM QCC
WELCOMES YOU ALL
FOR OUR SECOND PROJECT
PRESENTATION

STORM
238 02 80
QCC
DATA COLLECTION FOR CELL WISE B/D FREQ.

& HOURS (FROM APR‘05 - JUN‘05)
Hours
Cell Hours Frequency
Visteon 7.24 3 200
19 6 .3 3
Gear Housing 17.76 6
B D H o u rs
150
Filter Module 196.33 32
100
Honda Case Chain 25.47 6
cloc 35.57 8 50
Lube Module 50.79 14 0

Head FF 61.89 5
Case chain
Honda Case
Oil pan
ISX Fwh
Visteon
Module
Oil pan
MY 4.5
Honda
Housing
Head FF
Module
Cloc
Ford
Honda
Filter
Chain
Lub
Gear
Honda Oilpan 31 4
Ford Oilpan 4.17 1
Honda Casechain 23 6
Frequency
MY 4.5-Holset 12 5
ISX-Flywheel Hsg 82 17
40
32
Frequency
30
20
10
0
Case chain
Honda Case
Oil pan
ISX Fwh
Visteon
Oil pan
Module
MY 4.5
Honda
Housing
Head FF
Module
Cloc
Ford
Honda
Filter
Chain
Lub
Gear

STORM
238 02 81
QCC
QC STORY
Before QCC OLD CIRCUIT DIAGRAM

L1
FEED
CLAMPING CYLINDER
CYLINDER
Pressure
Switch
DECLAMP
CYCLE START
(L1) LIMIT SWITCH

CYCLE START TIMER

STORM
238 02 82
P QCC
QC STORY
FEED CYLINDER L2
After
L1
CLAMPING CYLINDER
QCC:
Z14 Z12
Z14 Z12
5/2 WAY VALVE

5/2 WAY VALVE
P P
CYCLE START
CYCLE START
(L1) LIMIT SWITCH (L2) LIMIT SWITCH

DECLAMP
P
STORM
QCC
MODIFIED CIRCUIT DIAGRAM 238 02 83

FEED CLAMPING
CYLINDER CYLINDER
L1 L2 Driver
Pressure
Switch
Driven
Compressed Air
Z14 Z12 Z14 Z12
P 5/2 WAY VALVE P

5/2 WAY VALVE
CYCLE Pinion
START
CYCLE
START
DECLAMP (L2) LIMIT

P SWITCH
(L1) LIMIT SWITCH
Spindle unit
MODIFIED CIRCUIT DIAGRAM

STORM
238 02 84
QCC
QC STORY
M
O
A D
F I
CAM F
T PLATE I
C
E A
T
R I
LIMIT O
SWITCH N
STORM
238 02 85
QCC
QC STORY
RANK ‘A’ –PM SCHEDULE

Sl.no Machine no Machine Description Cell Description Unit W 14 W 15 W 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Cummins
1 360102 LEAK TEST CLOC Cummins
2 089402 AMS WINNER XL CLOC Cummins
3 089501 AMS MCV 400 CLOC Cummins
4 089502 AMS MCV 400 CLOC Cummins
5 360137 LEAK TEST CLOC Cummins
6 081502 AMS MCV 300 DCX Cummins
7 081503 AMS MCV 300 DCX Cummins
8 089304 DAHLIH 1020 Gear housing Cummins
9 089301 DAHLIH 1020 Gear housing Cummins
10 089401 AMS WINNER Gear housing Cummins
11 089603 HARDINGE ISX Cummins
12 089102 AMS MCV 500 ISX Cummins
13 085831 SPM ISX Cummins
15 081402 AMS MCV 600 ISX Cummins
16 089202 DAHLIH 720 ISX Cummins
19 089204 DAHLIH 720 ISX Cummins
20 310101 VT 80 I ISX Cummins
21 310102 VT 80 II ISX Cummins
22 089302 DAHLIH 1020 M11 Cummins
23 089203 DAHLIH 720 SOVB Cummins
24 081401 AMS MCV 600 Midrange Cummins
25 89701 CHIRON LUBEMODULE Fleetguard
26 089507 AMS 400 PRIMERPUMP Fleetguard
27 89601 HARDINGE LUBEMODULE Fleetguard
28 89506 AMS 400 FILTER MODULE Fleetguard
29 33502 ACE LT20C FILTER MODULE Fleetguard
30 033108 GEDEE W EILER Head FF DEPT CODE PRO. CODE PAGE NO

STORM Fleetguard
238 02 86
QCC
QC STORY
EQUIPMENT RANKING CRITERIA

EQUIPMENT RANKING CRITERIA
CELL: CLOC
category
Criteria A B C
033007 033201 089402 089501 089502 086309 280412 360102
LATHE-I LATHE-II VMC-I VMC-II VMC-III DIA 5 SPMDIA 16 SPM

WASHING L/TEST-I
Failure w ould cause
Failure w ould cause
Hygiene & fire/explosion risk or
safety/hygiene risk or Other Equipment C C C C C C C C C
Safety serious environmental
environmental problem
problem
Machine quality defects Machine quality defects Machine quality defects

Quality C B C C C C C C C
w ith > 1% rejection w ith 0.3 - 1% rejection w ith < 0.3% rejection
Operating Takt time is 75% to

Takt time is 100% Takt time is < 75% C A C C A C C C B
Status 100%
Impact on Operation can be

No contigency for the
Production carried out in other Other Equipment B A A A A A B C B
equipment
(Contigency machines
Frequency of
Number of equipment Number of equipment Number of equipment
failures & C B A A A B C C C
failures is >10 / month failures is 5 - 10 / month failures is < 5 / month
Maintainability
Minor Number of minor stops is Number of minor stops Number of minor stops
C B B B B C C C C
Stoppages > 3 per 8 hours is 1 - 3 per 8 hour is <1 per 8 hour

STORM
238 02 87
QCC
QC STORY 2.0 OBSERVATION-COLLECT ANALYSE DATA
SPM SPINDLE UNIT

Driver
WORKING MECHANISM OF SPINDLE UNIT: Driven
Compressed Air
WHEN THE SPINDLE MOTOR Pinion

ROTATES IT TRANSMITS THE DRIVE TO
Lock Pin
THE WORM WHEEL AND WORM
SHAFT.THE DRIVE FROM THE WORM
SHAFT IS TRANSMITTED TO THE CLUTCH Spindle unit
DRIVER PLATE.
THE OUTPUT FROM THE VALVE

ACTUATES THE CYLINDER AND THE Driver
DRIVEN PLATE WHICH IS CONNECTED TO Driven
THE PISTON GOT ENGAGED TO THE
CLUTCH PLATE.THE PINION WHICH IS Compressed Air
Pinion
CONNECTED TO THE DRIVEN SHAFT WILL Lock Pin
ROTATES AND THE RACK (SPINDLE UNIT)
WILL STARTS TO MOVE DOWN. Spindle unit

STORM
238 02 88
QCC
QC STORY
TANGIBLE BENEFITS:
Cost of drill bit:Rs.1400/-

Cost of three Broken drill bits:3*1400=Rs.4200
Cost of clutch lock pin:Rs.400/-

Total no. of times Lock pin broken:3 times
Total cost of pin:3*400=Rs.1200
Cost of Pneumatic timer is:Rs.4822/-
Total cost saving of this project:4200+1200+4822=10622
Cost of Pressure switch used in this project:Rs.600/-

Net saving:10622-600=Rs.10022
STORM
238 02 89
QCC

Storm QCC: Welcomes You All For Our Second Project Presentation

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Storm QCC: Welcomes You All For Our Second Project Presentation

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QC STORY

WELCOMES YOU ALL

DEPT CODE PRO. CODE PAGE NO

• 1987 Awarded for best industrial

Sundaram Clayton QCC Projects trend - DCD

DEPT CODE PRO. CODE PAGE NO

SCL - Die Casting Division Customers

 Tata Holset  Mack, USA

 Sona Koyo Steering  Renault, USA

STORM QUALITY CIRCLE

NATURE OF WORKING AREA : PLANT MAINTENANCE

LEADER : D.SAMUEL RAJAN

MEETING DAY :EVERY WEDNESDAY AT

HIGH BREAKDOWN IN FILTER

DEPT CODE PRO. CODE PAGE NO

• Machine breakdown leads to delivery failure

• Delivery failure leads to Business loss

• TPM calls zero breakdown.

• The Breakdown of a machine affects the entire cell output.

Policy Deployment Objectives-X-matrix(DCD Machining Cell):

1 A 4 D a ily M o n it o rin g o f ' B ' & ' C ' ra n k M5/0c %B / d 9 5 %

1 A 2 D a ily P D C A o f ra n k ' A ' m a c h in e s 8 0 %

1A1 Reduce overall M/c B/D %(machine Wise) 0.60 0.30

1E1 Redcuce MTTR 4.5hrs 4hrs

OBJECTIVE ACTION PLAN

1.6 1.58 1.53

Less than 0.25% by the

CUSTOMER : FLEET GUARD

PRODUCT NAME : FUEL FILTER

PART NUMBER : 393588800

APPLICATION : FILTER ASSEMBLY

DELIVERY : FULLY MACHINED

MATERIAL : ALUMINIUM - ADC12

COMPONENT COST : $ 15.35

DEPT CODE PRO. CODE PAGE NO

DATA COLLECTION TEAM

PROBLEM SELECTION TEAM

SOLUTION SELECTION TEAM

DEPT CODE PRO. CODE PAGE NO

DATA COLLECTION FOR CELL WISE B/D FREQ.

DEPT CODE PRO. CODE PAGE NO

PARETO ANALYSIS FOR FILTER MODULE

Sno Machine Description B/D HRS %

4 033801 LT-20CLASSIC 1.75 0.9 140

5 085839 SPM 162 82.5 100

6 089505 AMS MCV400 11.25 5.69 60

7 089506 AMS MCV400 10 5.06 20 11.17 10 9.5 1.83 1.75 0

DEPT CODE PRO. CODE PAGE NO

PARETO ANALYSIS FOR FILTER MODULE

Sno Machine Description B/D Freq. % %

2 033501 ACE LT 20C 1 3.12 36

4 033801 LT-20CLASSIC 2 6.25 24

Total 32 100 85839 89407 33801 89506 33501 89505 33502

DEPT CODE PRO. CODE PAGE NO

DRILLING SPM - 085839

DEPT CODE PRO. CODE PAGE NO

Breakdown Hours & Breakdown Frequency

DEPT CODE PRO. CODE PAGE NO

FLOW CHART FOR FILTER MODULE CELL

ACE LATHE LT 20C ACE LATHE LT 20C

AMS MCV 400 AMS MCV 400

DEPT CODE PRO. CODE PAGE NO