Six-Sigma Green Belt Workshop (Pre-work)

Six-Sigma Green Belt

Pre-work
Focus of this program is not just on knowledge
enhancement but on practical application of SixSigma methodology for solving a real life concerns.
In order to make this easy, we will be focusing all
our workshop discussions and exercises a lot on
actual project allocated to you. It is therefore
necessary to gather some basic information,
historical data, facts and figures pertaining to
problems assigned to you.
SSGB, Pg - 1

Try to collect as much information as possible, as

Six-Sigma Green Belt Workshop (Pre-work)

Problem to be solved :

Rear Spring breakage

Current level :

1.3

Target level :

0.4
TEAM

Names

Role

Organization /
Dept

Sponsor
Mr. Madhu Bojja

Champion / Guide

Foundry

Mr. Manish Jain

Leader (Green
Belt)

QA

Mr. P.K.Das

Member

Customer Support

Mr. Vikram Raj

Member

QA

Mr. Vineet Sharma

Member

ERC

SSGB, Pg - 2

Six-Sigma Green Belt Workshop (Pre-work)

Background of the problem / failure mode(s)

SSGB, Pg - 3

Six-Sigma Green Belt Workshop (Pre-work)

Background of the Problem

Fill the rows as applicable :

Models /
vehicles
Lines
Suppliers
Part numbers

Where this
problem is
coming?

Where this problem

is not coming?

SK1613

LPS4018, LPT3118

Line 2

Line 3

M/s Akal Springs

M/s Jai, M/s Soni Auto

263232400118

278232400112,
284132400101

Zone /
customers

Declaration : The above information is authentic and I have the back-up evidences fo
SSGB, Pg - 4

Six-Sigma Green Belt Workshop (Pre-work)

Background of the Problem

Fill the failure mode tree and substantiate with data (IPTV

Declaration : The above information is authentic and I have the back-up evidences fo
SSGB, Pg - 5

CIR / Prowac
Dealer Name

Claim PCR Comp

Description
Srl
Year Aggr

Six-Sigma Green Belt Workshop (Pre-work)

Description

Chassis no.

Prod. Clai
Month m Dt

Mode Sub
l
Model

KM

ARVIND_MOTORS_PVT00046 2014
_LTD

SUSPE SPRING LEAF

NSION BROKEN - REAR

REAR RIGHT AUX

SPRING BROKEN

MAT373339D1N14 11.2013 5/16/20 1613

420
14

1613LPT

POPULAR MEGA
MOTORS (I) LTD

SUSPE SPRING LEAF

NSION BROKEN - REAR

REAR RIGHT LEAF

SPRING BROKEN

MAT373170D1J115 09.2013 1/10/20 1613

52
14

1613-SK 2696

01231 2013

Dealer Name

JAIKA_MOTORS_LTD

Claim Srl

PCR
Year

Comp
Aggr

Description

Description

Chassis no.

Prod.
Month

Claim Dt

Model

Sub Model

2513

KM

Sale
Date

CompRep-Dt

Customer Complaint

Investigation

2/18/201 5/8/2014
4

REAR LEAF SPRING BROKEN.

THIS VEHICLE REPORTED TO OUR

WORKS WITH ABOVE SAID
COMPLINT.ONOBSERVATION THE
REAR LH SIDE 4TH LEAF BROKEN
INTO PIECES AT ABOUT 485 MM
FROM THE CENTER BOLT HOLE
TOWARDS REAR END SIDE OF THE
SUSPENSION.CHECKED THE
SPRING SET CENTER BOLT ANDD U
CLAMP FOUND INTACT.NO ANY
MODIFICATION DONE ON THE
CHASSIS FRAME NOT SUSPENSION
SYSTEM.

10/28/20 1/10/2014
13

ABNORMAL SOUND FROM REAR

SUSPENSION AND VEHICLE OFF
ROAD ATALANCHERY WHICH IS
56KMSFROM OUR WORKSHOP.

WE DEPUTED OUR MECHANIC FOR

ONSITE REPAIR.DURING
INSPECTIONWE CHECKED AND
FOUND THAT REAR RH SIDE
SECOND AUXILIARY LEAF SPRING
WAS IN BROKEN AND 1ST AUX. LEAF
WAS IN CRACKED CONDITION.ALSO
WHILE DISMANTLED BOTH SIDE
LEAF SPRINGS ASSY AND FFOUND
THAT CENTRE HOLE PRESENT IN
MOST OF THE LEAF SPRING WAS IN
Investigation
ELONGATED CONDITION AND
CENTRE BOLT HAVING EXCESS
PLAYDUE TO THIS HOLE
ELONGATION.MOST OF THE SPRING
LEAVAES PRESENT IN THE ASSY
WERE N SEVERELY RUSTED
CONDITION.

Sale Date

Comp-RepDt

Customer Complaint

01865 2013

SUSPE SPRING LEAF

NSION BROKEN - REAR

REAR RIGHT LEAF

SPRING BROKEN

MAT373172D1H10 08.2013 12/7/20 1613

457
13

1613-SK 2779

10/28/20 12/6/2013
13

REAR SPRING LEAF BROKEN

REAR LHS 2ND SPRING LEAF

FOUND BROKEN. NO MODIFICATION
OBSERVED IN SUSPENSION. [MAKENOT FOUND IN LEAKF SPRING]

BHANDARI_AUTOMOBI 00820 2013

LES_PVT_LTD

SUSPE SPRING LEAF

NSION BROKEN - REAR

REAR RIGHT LEAF

SPRING BROKEN

MAT388344D2H08 08.2013 12/27/2 1613TC1613TC- 2915

337
013
LPT

9/27/201 12/18/201
3
3

LEAF SPRING BROKEN.

OBSERVED REAR HELPER SET MAIN

LEAF SPRING BROKEN FROM
MIDDLE. NO OUTSIDE IMPACT AND
NO SUCH MODIFICATION ON
SUSPENSION FOUND. SUSPECTED
LEAF SPRING MATERIAL
HARDENING IMPROPER.

ABT_INDUSTRIES_LTD 00926 2013

SUSPE SPRING LEAF

NSION BROKEN - REAR

REAR RIGHT LEAF

SPRING BROKEN

MAT373085D2F06 06.2013 3/19/20 1613

470
14

1613-SK 2936

2/20/201 3/15/2014
4

REAR RHS SIDE SUSPENSION

NOISE

IN OUR INSPECTION FOUND 8TH

AND 7TH LEAF BROKEN WHILE THE
VEHICLE IN RUNNING.WE
RECEIVED THE VEHICLE ONLY THE
HALF OF THE LEAF OF 7TH AND
8TH.DID NOT FIND OUT THE
REMAINING LEAF.

ARVIND_MOTORS_(P)_ 01968 2013

LTD

SUSPE SPRING LEAF

NSION BROKEN - REAR

REAR RIGHT LEAF

SPRING BROKEN

MAT373170D1K12 10.2013 11/20/2 1613

730
013

1613-SK 3015

10/31/20 11/19/201
13
3

REAR SUSPENSION NOISY

FOUND REAR LH MAIN LEAF

CUT/BROKEN CAUSING THE
COMPLAINT

SSGB, Pg - 6

Six-Sigma Green Belt Workshop (Pre-work)

Taper Matrix of the Problem(s)

MON-YY

ProdQty

0-3

0-4

0-5

0-6

0-7

0-8

0-9

0-10

0-11

0-12

0-13

0-14

0-15

0-16

0-17

0-18

0-19

0-20

0-21

0-22

0-23

0-24

Total
Cmpls
61

Apr-12

6564

457

762

1066

1523

2438

2895

3809

5180

6551

8227

8836

9141

9141

9141

9141

9141

9141

9141

9141

9141

9293

May-12

4646

861

1507

1507

1937

3013

3874

5381

6457

7749

8610

9255

9901

9901

9901

9901

9901

10116

10116

10116

10116

10331

48

Jun-12

4912

407

814

2036

3868

7329

8958

12215

16490

19748

20562

21987

22801

23005

23208

23208

23208

23616

23616

23616

23819

23819

23819

117

10164

Jul-12

5805

172

345

861

1378

2067

3618

4823

5857

7063

7752

8958

9475

10164

10164

10164

10164

10164

10164

10164

10164

Aug-12

7299

274

959

1918

3699

5754

7946

9453

10549

11645

12193

12741

13015

13152

13152

13426

13564

13564

13564

13564

13564

Sep-12

8321

481

1562

2163

2524

3365

3726

4206

4807

5168

5288

5528

5528

5769

5889

5889

5889

Oct-12

7589

132

395

1318

1977

3953

5798

7379

8565

9751

10673

11069

11596

11596

11991

11991

12123

12123

12123

Nov-12

4556

219

658

1536

2634

3292

4609

4829

4829

5048

5048

5707

5926

5926

6146

6146

6146

6146

Dec-12

3681

543

543

1630

2173

2717

3532

3532

3532

4618

5162

5705

5705

5705

5705

Jan-13

5117

782

1563

1759

2541

3127

3909

4886

5863

6645

7622

8403

10162

10358

10358

10358

Feb-13

3588

279

557

557

1115

1115

1115

1394

1394

2230

2508

2787

2787

2787

2787

Mar-13

5657

884

1061

1061

1591

1768

3535

4950

6187

7248

7601

7601

Apr-13

5188

386

1349

1928

2120

3277

3662

4819

5590

5975

May-13

5937

9432

Jun-13

3447

Jul-13

3899

Aug-13

3460

Sep-13

3035

Oct-13

3966

252

Nov-13

3612

Dec-13

505

842

1347

2190

4042

5221

6737

8590

9096

870

870

1160

5222

6963

7543

9574

9864

10734

769

2565

3591

4617

6412

7694

867

1734

3468

5202

5202

5491

659

988

2306

2965

3295

252

1261

1513

2017

2521

277

1107

1938

3599

4153

2276

439

439

1757

2197

Jan-14

3811

262

262

262

Feb-14

4899

Mar-14

4867

Apr-14

4746

290

SSGB, Pg - 7

59
99
49
92
28
21
53
10
43
31
56
37
30
19
10
10
15
5
1

Six-Sigma Green Belt Workshop (Pre-work)

Trends (6MM & 3 MMA)

SSGB, Pg - 8

Six-Sigma Green Belt Workshop (Pre-work)

Trends (6MM & 3 MMA - 1613)

SSGB, Pg - 9

Six-Sigma Green Belt Workshop (Pre-work)

Dealer Wise Analysis

SSGB, Pg - 10

Six-Sigma Green Belt Workshop (Pre-work)

Kilometer Wise Analysis

SSGB, Pg - 11

Six-Sigma Green Belt Workshop (Pre-work)

Process Steps

Capture step-by-step pics and complete below flow diagra

SSGB, Pg - 12

Six-Sigma Green Belt Workshop (Pre-work)

Input Material Details

Please fill the table below for all items which are under
project scope along with key interface parts :

SSGB, Pg - 13

Items

Suppliers

Rear Spring bracket

EFFCO, Fie Sphero

Spring pin

Multitech, JMT

Rear Spring Shackle

EFFCO, Fie Sphero

Bottom Saddle of
Rear Axle

TMLDL

U-bolt

Steel City, G.S.Auto

Six-Sigma Green Belt Workshop (Pre-work)

Drawings

SSGB, Pg - 14

Six-Sigma Green Belt Workshop (Pre-work)

PFD

(attach PFD of the

concerned process)

SSGB, Pg - 15

Six-Sigma Green Belt Workshop (Pre-work)

FMEA

(attach FMEA of the

concerned process
If possible, try to get
DFMEA from ERC or
Supplier)

SSGB, Pg - 16