Reduction In External Customer Defects (Case Study)

Step 1: Confirmation of the Actual condition

Theme – To eliminate User Plant defect of Anti lock

Braking System (ABS) Lamp continuous ON in
Scorpio Refresh Vehicle

Chapter No. 7.1 Quality Maintenance Pillar Activity Report Page No. 191 Slide 1 of 612
 Reduction In External Customer Defects (Case Study)
Step 1: Confirmation of the Actual condition
Pareto analysis of User Plant Defects in F15
8 7 95%97%98%
100% 100%
91%93%
No of Incidences

84% 86%88%90%
6 76%78% 79%81%83% 75%
5 71%72%74%
64%66% 67%69%
4 4 59%62%
55%
4 3 45%
3 48%52% 50%
40% 2 2 2 2 2
34%
2 28% 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 25%
21%
12%
0 0%

Concerns

User Plant Defect Data : Axle Assembly.

Mfg /
Sr No Stage Defect Vendor / F15 Apr-14 May-14 Jun-14 July-14 Aug-14
Design
Shaft Assembly ABS Lamp Continuous ON in Scorpio
1 Mfg 7 - - - 0 7
fitment Refresh Vehicle
Hand brake Cable Cable fitment Not Possible in Thar
2 Design 5 5 0 0 0 0
fitment Vehicle
Hand brake Cable
3 Wrong Cable fitment in BMT axle Mfg 4 0 0 4 0 0
fitment

Chapter No. 7.1 Quality Maintenance Pillar Activity Report Page No. 191 Slide 2 of 612
 Reduction In External Customer Defects (Case Study)
Step 1: Confirmation of the Actual condition
Defect Description:
ABS sensor Lamp on dash board Non ABS Shaft Subassembly fitted in place of
Continuously ON ABS Shaft sub assembly in Scorpio Refresh
Rear Axle Causing ABS Lamp Continuous ON
& Vehicle ABS System failure
Wrong Shaft Assembly fitted on
Rear Axle - Non ABS Shaft Sub
assembly fitted in place of ABS
Shaft Sub assembly

Locking collar for Teeth on Toner

NON ABS Ring for ABS
System

ABS Lamp Continuously glowing

in vehicle dashboard indicates
Vehicle ABS System failure

Non ABS shaft ABS shaft

subassembly subassembly

Chapter No. 7.1 Quality Maintenance Pillar Activity Report Page No. 192 Slide 3 of 612
 3
2
1
Sr. No.

axle
Defect
Stages

Vehicle
Vehicle

Chapter No. 7.1

ABS Lamp
Stages
Machine No/

Wrong Cable
Phenomenon

fitment in BMT
Scorpio Refresh

Possible in Thar
Machine No/

Continuous ON in

Cable fitment Not

(QA Matrix)

Clean parts in GPM

1779

Kitting of parts in assembly

trolley
RTV sealant bead application
on beam

Quality Maintenance Pillar

Fitment of GC assy in beam

Axle Sr. Number punching

Drain plug & breather plug

fitment
G Shaft sub assembly fitment in
beam

Brake shoe plate tightening

G
G
Hand brake cable fitment

Brake drum fitment

Air testing

Activity Report Page No. 192

painting of Axle
D

Rear Axle Buy off Inspection

D
D

Fitment at User plant

Vehicle Testing at User plant
D
Step 2: Investigation of Processes in which Defects Occur

9
9
9

Severity
Reduction In External Customer Defects (Case Study)

4
5
7

Occurrence
Detection
SOD
7 252 3
9 405 2
9 567 1

Priority
Slide 4 of 612
 Reduction In External Customer Defects (Case Study)
Step 3 : Survey & Analysis of 4M conditions
4M conditions
Plant : Kandivli PU / Shop / Dept. : Axle PU Cell / Circle : Axle Assembly
Machine / Equipment / Workstation Name : Shaft Sub
Machine / Equipment / Workstation No. : 1
Assembly fitment in Beam
Defect : ABS Lamp Continuous ON in Scorpio Refresh Vehicle
√ Standard available & followed Standard not available
Legend : -
Standard available but not followed Standard difficult to follow

Parameter Should be value ( Spec.) Actual value Ok / Not Ok Status

Man Operator Skill Q2 Q2 OK √
RTV sealant applicator air
Machine 5 Kg/cm2 5 Kg/cm2 OK √
pressure
ABS Axle – ABS Shaft sub assembly
ABS Axle - NON ABS shaft sub
with toner ring
Shaft sub assembly selection assembly with locking collar . Not Ok
NON ABS Axle – Non ABS shaft sub
assembly with locking collar.

Method Application of RTV sealant On bearing carrier face On bearing carrier face Ok √

Complete coverage of RTV Sealant on Complete coverage of RTV

RTV sealant coverage Ok √
bearing carrier face Sealant on bearing carrier face
Fixture for application of RTV
Fixture to be used for RTV application Fixture used Ok √
sealant
ABS Axle – ABS Shaft sub assembly Axle shaft sub assembly with
Not OK
Provide correct shaft sub assembly with toner ring locking collar
on line NON ABS Axle - Non ABS shaft sub
NA
assembly with locking collar.
Material Beam with sensor hole for ABS
OK √
Beam with sensor hole for ABS axle axle
Provide correct beam on line
Beam without sensor hole for Beam without sensor hole for
Non Report Page No.
Chapter No. 7.1 Quality Maintenance Pillar Activity Non ABS axle 187 OK √ 5 of 612
Slide
ABS axle
 Reduction In External Customer Defects (Case Study)
Step 3: Survey & Analysis of 4M Conditions
Why-Why Analysis

Not Ok Condition /
Why 1 Why 2 Why 3 Root Cause Idea Countermeasure
Abnormality

Shaft sub
No clear To differentiate Provide color code.
ABS Axle - NON ABS shaft Wrong selection assembly for ABS
Operator identification for ABS & Non ABS 1) Yellow for "ABS"
sub assembly with of shaft sub axle & Non ABS
mistake ABS & Non ABS Shaft sub 2) Black for "Non
locking collar assembly axles kept in one
shaft sub assembly Assembly ABS"
trolley

Axle shaft sub

Single trolley used Add shaft sub
assembly to be
for both types of assembly into the
supplied in kitting
shaft sub assembly kitting trolley
Trolley

No detection Provide detection at

No detection To Provide
mechanism subsequent stage for
mechanism detection
available presence of tonner
available mechanism
ring

Chapter No. 7.1 Quality Maintenance Pillar Activity Report Page No. 193 Slide 6 of 612
 Reduction In External Customer Defects (Case Study)
Step – 4: Problem countermeasure & Study Restoration
KAIZEN 1

BEFORE AFTER
Color identification for ABS & Non ABS
1) Yellow for "ABS"
axle shaft sub assembly was same.
2) Black for "Non ABS
( Yellow)

ABS shaft
ABS & Non sub Non ABS shaft sub
ABS shaft assembly assembly
having same with Yellow identified with
color code color Black Color

Chapter No. 7.1 Quality Maintenance Pillar Activity Report Page No. 194 Slide 7 of 612
 Reduction In External Customer Defects (Case Study)
Step – 4: Problem countermeasure & Study Restoration

KAIZEN 2
BEFORE AFTER
 Axle shaft sub assembly trolley given  Axle shaft sub assembly added in
directly on line for further assembly. kitting trolley .

Axle shaft sub assembly in

kitting trolley

Chapter No. 7.1 Quality Maintenance Pillar Activity Report Page No. 195 Slide 8 of 612
 Reduction In External Customer Defects (Case Study)
Step – 4: Problem countermeasure & Study Restoration

KAIZEN 3
BEFORE AFTER
 No detection for correct shaft sub  Detection of correct shaft sub assembly
assembly fitment . through ABS sensor hole and providing
confirmation yellow paint mark .

Toner ring
fitted

Protective cap
on ABS sensor
hole

Confirmation
checkmark
on Axle by
next stage
operator

Chapter No. 7.1 Quality Maintenance Pillar Activity Report Page No. 195 Slide 9 of 612
 Reduction In External Customer Defects (Case Study)
Step – 4: Problem countermeasure & Study Restoration

Results:

Wrong shaft sub assembly fitment

8
7
7
6
5
In Nos

4
3
2
1
0 0 0 0 0
0
Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15

As this is Sporadic Defect, Step-4 to Step-8 are not applicable.

Chapter No. 7.1 Quality Maintenance Pillar Activity Report Page No. 195 Slide 10 of 612
 Reduction In External Customer Defects (Case Study)
Step – 9: Determination of Standard Values for inspection
Product Name - Rear Axle
Shaft sub assembly
Quality Maintenance Matrix
Process Name -
fitment on Axle
Shaft sub assembly
Machine / Stage -
fitment stage

RTV sealant RTV sealant Selection of Toner Identification of

Q Parameter of Process /
application on application Ring / Locking Axle shaft sub Axle beam
Q Component of Machine
bearing carrier fixture Collar assembly

For ABS Axle - Toner For ABS – Yellow For ABS – Sticker
Manual sealant ring Colour Code ‘ABS’
Inspection Item Air Pressure
application For Non ABS Axle – For Non ABS – for Non ABS –
Locking collar Black Colour Code Sticker ‘NON ABS’
Measurement Tool Visual Pressure Gauge Visual Visual Visual
Specification - 5 kg/cm2 - - -
Frequency 100% Start of shift 100% 100% 100%
Person in Charge Operator Operator Operator Operator Operator
Correct shat sub assembly
1 fitment on axle beam as per √ √ √
model identification
Correct Toner Ring / locking
2 collar fitment on axle shaft as per √ √
model
RTV Sealant Application On bearing
3
carrier face √ √ √ √
Complete coverage of RTV Sealant
4
on bearing carrier face √ √ √ √
Chapter No. 7.1 Quality Maintenance Pillar Activity Report Page No. 196 Slide 11 of 612
 Reduction In External Customer Defects (Case Study)
Step – 9: Determination of Standard Values for inspection
Audit Check sheet Updated -
W105 Rear Axle Assembly - Audit checksheet Audit Date - 24.09.14
Axle Part No - 0502AAA7070N Inspected By - A J Deshmukh

Axle Description - W105 Rear Axle ABS, 4.3 Ratio Approved By - Pawan Rajput

Sr No Concern Process check Status Status Status Status Status Status

Axle Sr no Axle Sr no Axle Sr no Axle Sr no Axle Sr no Axle Sr no
14-145892 14-145893 14-145894 14-145895 14-145896 14-145897
1 Chips in Beam Check for Burr Check for Burr √ √ √ √ √ √
2 Oil seal fittment Oil seal fittment Pefectly fitted √ √ √ √ √ √
GC Assly fittment Model Part no written on
3 Ratio tag as per model √ √ √ √ √ √
(wrong ratio) GC Assly + Ratio Tag
GC Assly fittment Yellow mark + white mark for
4 Cover Bolt Torquing √ √ √ √ √ √
Cover Bolt Loose torquing.
Matchmark on drain plug for
Drain Plug Cross
5 Torquing with yellow mark correct fitment confirmation after √ √ √ √ √ √
fitted
torqueing
6 Shaft Assembly wire ring fittment should rotate √ √ √ √ √ √
ABS - Yellow Color Code +
identification on trolley + binning
in parts trolley
7 Shaft Assembly Visual Non ABS - Black Colour Code + √ √ √ √ √ √
identification on trolley + binning
in parts trolley
ABS - Yellow mark on beam
W105 4.3 ABS- Yellow
strip
Schedule board as per brake
8 Brake Shoe W105 - 3.73 - KBX strip √ √ √ √ √ √
shoe sticker description
W105 - 4.3 Non ABS - No
strip
LH Side Yellow Colour Left side' strip on LH side of
9 Handbrake Cable Strip & RH side no colour brake cable & yellow mark on √ √ √ √ √ √
code cable
W105 ABS - Circular
groove on face
W105 NON ABS - Circular Groove identification on OD ABS
10 Toner Ring √ √ √ √ √ √
groove on face toner ring
U205 ABS - No groove on
face

Chapter No. 7.1 Quality Maintenance Pillar Activity Report Page No. 197 Slide 12 of 612