Six Sigma BB Project

ACMA

ACT

Shainin DOE, Version: 1.1,Jan03

Six Sigma BB Project Project Number : 01

Project Description

Bore Diameter 35 mm Unclean in Throttle Body AC-35.

ACMA

ACT

Shainin DOE, Version: 1.1,Jan03

DOE Project Description

Phases Compl. Date 20-07-04 22-07-04 03-08-04 10-08-04

Project reference: 001/04 -05 Date of Start : 20/07/04

Phase-1 Phase-2 Phase-3 Phase-4

Name of BB - Mr. Arvind Gupta (ACMA-ACT) Team members - Mr. N.Prakash, Mr.I.P. Batra (UCAL Fuel Systems Limited,Gurgaon)

Annual Cost Of Poor Quality: Rs, 1,78,610/ACMA

ACT
3

Shainin DOE, Version: 1.1,Jan03

DOE Project
Cost of Poor Quality Breakup
Rework Cost Machining Cost Raw Material Cost : NIL : Rs 56,448/: Rs.1,22,162/-

Intangible Savings
1. Internal Customer Satisfaction. 2. Smooth flow of products. 3. Learning of Systematic Approach to solve the problem. 4. Breakthrough in the company towards the attitude.
ACMA
ACT
4

Shainin DOE, Version: 1.1,Jan03

Phase 1- Definition

Problem definition

- Bore Unclean(reduced from 0.56 % to ZERO.)

Response definition - Attribute Instrument to be used - Visual R&R study details - Not Required Potential SSVs from FMEAs\ Brain storming Brain storming
ACMA
ACT
5
Shainin DOE, Version: 1.1,Jan03

Phase-1- Definition Problem & Response Definition

Problem Statement
- Bore diameter 35 mm unclean in Throttle Body AC-35.

Response to be measured
- Bore Unclean ( Attribute)

Specification
- No Unclean

Instrument used to verify the Response

- Visual

Least Count of the instrument

- Not Applicable
ACMA
ACT
6

Shainin DOE, Version: 1.1,Jan03

Phase 1 Definition R&R study details

Is R&R study required for the Measurement system - No Result of R&R study % E.V. - Not Applicable % A.V. - Not Applicable %R&R - Not Applicable

ACMA

ACT

Shainin DOE, Version: 1.1,Jan03

Phase 1 Definition Listing Potential Source of Variation

Y = f (X)
Where Y= Response ( Unclean in Bore) X = Suspected Source of Variation (SSV)

SSVs are:
1. 2. 3. 4. 5. Mounting Hole Dia. 6.5 +0.2/+0 Mounting Hole Position w.r.t. Bore (X axis) 24 +/- 0.05 Mounting Hole Position w.r.t. Bore (Y axis) 28 +/- 0.05 Mounting Face Flatness 0.05 Max Step in Bore Diameter 35 at Casting Stage .
ACT
8

ACMA

Shainin DOE, Version: 1.1,Jan03

Phase 1 Definition Drawing/Photograph

Locating Holes Dia 6.5+0.2/0.0 Mounting Face 0.05 max.

Throttle Body

35 Bore Unclean
ACMA

24 +/- 0.05

28 +/-0.05

ACT

Shainin DOE, Version: 1.1,Jan03

Phase 1 Definition Drawing/Photograph

Sensor Bracket

Throttle Valve

Throttle Body
ACMA
ACT
10

Shainin DOE, Version: 1.1,Jan03

Phase 1 Definition Drawing/Photograph

Locating Pins Clamp

ACMA

Fixture

Boring Bar

ACT

11

Shainin DOE, Version: 1.1,Jan03

Phase 2 Measure and Analyze

Shainin DOE Tool selection - Paired Comparison Data collection - Yes Analysis of Data - Yes Conclusion based on data - Yes

ACMA

ACT

12

Shainin DOE, Version: 1.1,Jan03

Phase2 Measure and Analyze Tool selection

Initial Tool selected Since the SSVs- Mounting Holes Diameter 6.5 mm
, Hole Positions w.r.t Bore center ( x & y coordinates) 24 & 28 mm and Mounting Face Flatness can be checked on Good & Bad Parts both , D.O.E.

Tool selected was Paired Comparison.

13

ACMA

ACT

Shainin DOE, Version: 1.1,Jan03

Phase 2 Measure and Analyze

Data Collection
Good and Bad parts selected based on the Response( Bore unclean) 8 Best of Best (Good) and 8 Worst of Worst (Bad) parts selected based on the Response. SSVs Dimension 28+/- 0.05 , 24 +/-0.05 , Hole Size 6.5 +0.2/-0 & Flatness of mounting face 0.05 max. measured on both Good and Bad parts and analyzed for the counts.
ACMA
ACT
14
Shainin DOE, Version: 1.1,Jan03

Phase 2 Measure and Analyze Data Collection and analysis

S.N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 COUNT = Dimn 28+/-0.05 27.95 27.95 27.96 27.96 27.96 27.96 27.97 27.97 27.97 27.97 28.03 28.03 28.04 28.05 28.06 28.06 ZERO Result G G G G G B G B B G B B B B B G
Hole 1

S.N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 COUNT =

Dimn 28+/-0.05 27.93 27.94 27.96 27.97 27.98 27.99 28.00 28.00 28.01 28.03 28.04 28.05 28.05 28.06 28.06 28.06 5.5

Result B B G G B B B B B G G B G G G G

Hole 2

Not A Cause

Not A Cause
15

ACMA

ACT

Shainin DOE, Version: 1.1,Jan03

Phase 2 Measure and Analyze Data Collection and analysis

S.N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 COUNT = Dimn 24+/-0.05 23.94 23.95 23.95 23.95 23.95 23.95 23.96 23.96 23.97 23.97 23.97 23.98 23.99 24.00 24.00 24.03 5 Result B B B G B B B B G G G B G G G G Hole -1 S.N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 COUNT = Dimn 24+/-0.05 23.97 23.97 23.98 23.99 24.00 24.01 24.03 24.05 24.05 24.05 24.05 24.05 24.05 24.06 24.07 24.07 Result B B B B B B B B G G G G G G G G Hole -2

Not A Cause

ACMA

10
ACT

One of the Cause

16

Shainin DOE, Version: 1.1,Jan03

Phase 2 Measure and Analyze Data Collection and analysis

DATA COLLECTION FOR SSV'S
S.N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 COUNT = Hole Dia 6.5+0.2/0.0

Hole 2

Result B B B B B B B B G G G G G G G G

Hole 1

S.N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Hole Dia 6.5+0.2/0.0

Result B B B B B B B B G G G G G G G G

6.61 6.62 6.63 6.63 6.63 6.64 6.64 6.64 6.66 6.66 6.66 6.66 6.66 6.66 6.67 6.67 16

6.62 6.62 6.62 6.63 6.63 6.63 6.65 6.66 6.66 6.66 6.66 6.67 6.67 6.67 6.67 6.67 12

Root Cause

COUNT =

ACMA

ACT

Root Cause 17

Shainin DOE, Version: 1.1,Jan03

Phase 2 Measure and Analyze Data Collection and analysis

S.N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 COUNT = Flatness of Mounting Face 0.05 Max. 0.020 0.020 0.025 0.025 0.025 0.026 0.028 0.028 0.030 0.035 0.035 0.038 0.040 0.042 0.045 0.050 ZERO Result G G B G G G B G B G B B B B B G

Not A Cause ACT

18
Shainin DOE, Version: 1.1,Jan03

ACMA

Phase 2 Measure and Analyze Data Collection and analysis

Analysis:
S.N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Hole Dia 6.5+0.2/0.0

Result B B B B B B B B G G G G G G G G

6.61 6.62 6.63 6.63 6.63 6.64 6.64 6.64 6.66 6.66 6.66 6.66 6.66 6.66 6.67 6.67

Since the count is =16, Mounting Hole size Dia 6 mm is one of the strongest cause of the problem

ACMA

ACT

19

Shainin DOE, Version: 1.1,Jan03

Phase 2 Measure and Analyze Data Collection and analysis

Conclusions:
S.N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 COUNT = Hole Dia 6.5+0.2/0.0

Inference from the data

Result B B B B B B B B G G G G G G G G

6.61 6.62 6.63 6.63 6.63 6.64 6.64 6.64 6.66 6.66 6.66 6.66 6.66 6.66 6.67 6.67 16

GOOD ---6.66 ~ 6.67 mm BAD------6.61 ~ 6.64 mm Drg. Spec. 6.50~6.70mm Variation in the Process 6.61 ~ 6.67 = 0.06 mm(within Spec.) Locating Pin size---6.57mm Clearance between Pin and locating hole GOOD Max.6.67-6.57=0.1mm Min.6.66-6.57=0.09mm BAD Max.6.64-6.57=0.07mm Min 6.61-6.57= 0.04mm
ACT
20

ACMA

Shainin DOE, Version: 1.1,Jan03

Phase 3 Improvement
Conclusions ( Root Cause):
From the analysis ,it is evident that clearance between Locating Pin & Mounting hole varying from 0.09 to 0.1 result in GOOD Product wherein clearance ranging between 0.04 to 0.07 mm result in BAD product. So we need to maintain the clearance between Pin & Hole min 0.09 mm.
ACMA
ACT
21

Shainin DOE, Version: 1.1,Jan03

Phase 3 Improvement
Opportunities available
Option No.1:To Change the Spec of Hole Size from present 6.5+0.2 to 6.66+0.06mm ( To maintain min clearance 0.09) which requires drill size change & also sought approval from customer as the drawing is customer approved. Subsequent fitment at the customer end was also a constraint, so

Option no.1 was ruled out.

Option no.2 : To modified the Pin size from present 6.57 to 6.52 to maintain minimum clearance of 0.09 mm ( As per data for GOOD parts).Option

-2 ,Implemented.
ACT
22

ACMA

Shainin DOE, Version: 1.1,Jan03

Phase 3 Improvement

After the countermeasure taken, 100 % inspection of the parts carried out visually on the machine for bore unclean problem. Rejection found to be ZERO out of total 15,000 parts made till now.
ACMA
ACT
23

Shainin DOE, Version: 1.1,Jan03

Phase 4 - Control
Tool drawing Has been modified & standardized for the locating pin size 6.57 to 6.52 mm. FMEA has been updated. Control Plan( maintenance) has been revised for the pin change frequency.

ACMA

ACT

24

Shainin DOE, Version: 1.1,Jan03

Phase 4 - Control
MATERIAL :EN 31 HARDNESS :40~50 HRC QUANTITY :1 NOS ALL SHARP CORNERS TO BE CHAMFERED

ACMA

ACT

25

Shainin DOE, Version: 1.1,Jan03

FUNNELING BY 6 SIGMA
Bore Unclean DOE TOOL Paired Comparison DOE TOOL

90 80 70 60 50 40 30 20 10 0 1st Qtr 2nd Qtr East West North

ACMA

ACT

3rd Qtr

4th Qtr

26

Shainin DOE, Version: 1.1,Jan03

Phase 4 - Control

Variation analysis:
Since the variation in the hole size is less than 50 % of the tolerance , Pre-control chart has been implemented on the machine to record the variation in the hole size due to drill worn out at hole drilling stage.

ACMA

ACT

27

Shainin DOE, Version: 1.1,Jan03

Phase 4 - Control

Scatter plot has been introduced on the machine to record the no .of parts produced and the variation in hole size to find out (optimize) Tool ( drill ) Life.

ACMA

ACT

28

Shainin DOE, Version: 1.1,Jan03

Phase 4 - Control

Horizontal Deployment Throttle Body AC-38

ACMA

ACT

29

Shainin DOE, Version: 1.1,Jan03

Phase 4 - Control
Although problem now seems to be easy ,but it was difficult in the beginning to find out the root cause of the problem as generally it is perceived that more clearance between hole & pin will cause the problem whereas in this case , it was a case of less clearance causing the problem.

Learning:
To avoid the twist of the part while mounting on to the fixture ,Min clearance between the locating pin & hole shall be kept 0.1 mm approx( Subject to fitment and function of
the part).
ACMA
ACT
30
Shainin DOE, Version: 1.1,Jan03

Project Completed

ACMA

ACT

31

Shainin DOE, Version: 1.1,Jan03

ACMA

ACT

32

Shainin DOE, Version: 1.1,Jan03