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ROOT CAUSE ANALYSIS OF INLET HOLE AND

LEAK OFF HOLE OPERATION MISSING
PROBLEM IN CRI BODY USING SHAININ
APPROA....

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 ROOT CAUSE ANALYSIS OF INLET HOLE AND LEAK OFF HOLE OPERATION MISSING PROBLEM IN CRI BODY USING SHAININ APPROACH

ROOT CAUSE ANALYSIS OF INLET HOLE AND LEAK OFF HOLE

OPERATION MISSING PROBLEM IN CRI BODY USING SHAININ
APPROACH
1
Nikhil Ghag, 2Shashank Pansari, 3Himanshu Sawant
1,2 3
Mechatronics department, MIT, Manipal, Dept. of manufacturing of CRI, BOSCH Ltd., Nashik
Email: 1nikhilghg3@gmail.com, 2 Himanshu.Sawant@in.bosch.com,3 Shashank.pansari@manipal.edu

Abstract: The two major challenges that industries are facing today are continuous improvement in productivity and quality
of the product. Bosch Production System (BPS) is one of the leading manufacturers in Diesel system equipment’s. Fuel
Injector is main product of Bosch India Nashik. This plant produce around 10,000 injector per day. They are having mass
production, it may happen that in such mass production their might be some part with operation missing. Such operation
missing parts contribute a lot in defect cost. There are two holes in injector body inlet hole and leak off hole with dia. 2.2 mm
and 1.43 mm. This holes are gun-drilled into the forged body. Many times it is observed that drilling operation is half done,
there might be many root causes like drill breakage, drill blunt, interruption in machine due to coolant level low etc. there was
need of finding dominant root cause and eliminate it. Bosch Production System (BPS) - one of the leading manufacturers in
Diesel system equipment’s, has been successfully employing the efficient statistical tool ‘Shainin’ for the root cause
identification and Design of Experiments (DOE) techniques for analysis and optimization of the quality related issues. Shainin
is popular being a simplest and effective tool to employ in solving the manufacturing related problems. So it was decided to
go with Shainin and find the dominant root cause. Shainin® system could be effectively used for solving the problems with
the theory that “there is a dominant cause of variation in the process output that defines the problem” and it is analogous to
Pareto principle of ‘vital few and trivial many’ or ‘20/80 principle’. The categorization of the problem done in order to choose
the best effective techniques such as Component search, Paired comparison, Concentration chart, Strategy diagram etc.
Classification of the problem that is GreenY (as termed in Shainin® system) is done as Property, Profile, Defect or Event.
Event subcategorized as destructive or malfunction event.

Keywords: Shainin® Methodology, Root Cause Analysis (RCA), RedX.

1. INTRODUCTION

Main product of Bosch at Nashik is Common rail

injector. The body is the biggest part of the assembled
Common Rail Injector (CRI). It has to resist high
pressures up to 2,000 bar. Moreover there is a zero
tolerance for defected parts, because it is an element of
the common rail system, which is a sensitive
component of any vehicle. The CRI body has defined
surfaces, which can be adjust for every customer and
their needs. But all of them have the same
specifications regarding the surface quality. The body
has internal and external surfaces, which has to be
manufactured out of the forged raw material. Every
surface is important for the functionality of the injector
and consequently crucial for every vehicle powered
with a diesel engine. The Across flat (A/F) surfaces
(created by Milling operation) in CRI Body serves the
purpose to mount the injector within the common rail
system and hence is as important as any other
operation.
1
Fig.1. Injector mounting in Engine
Nowadays quality has become important criteria to be
in market. This is possible only through quality
improvement techniques like Shainin RedX®, Six Sigma
etc.
1.1 Shainin RedX®
Shainin has task domain character. Shainin is a
problem solving methodology for reduce the process
variation. What it make differs from other problem
solving technique is its convergent approach to
identify the root cause, effect to Cause(Y to X). To
apply the convergent approach it is necessary to
properly know output Y. Complete knowledge of
process, failure symptoms, contrasts between good
and bad parts is key way of knowing output Y.
Progressive and convergent strategy is main
component of finding the Root cause by deep
 ROOT CAUSE ANALYSIS OF INLET HOLE AND LEAK OFF HOLE OPERATION MISSING PROBLEM IN CRI BODY USING SHAININ APPROACH

investigation of parts. The key assumption of whole

methodology is that there is dominant root cause which
is responsible for process variation.

Shainin Approach is called FACTUALTM: Focus,

Approach, Converge, Test, Understand, Apply,
leverage.

Focus: Defining project and making a project

frame.
Approach: Develop solution strategy, Verification of
measurement system.
Converge: Convergence towards solution, best parts
v/s worst parts comparison & find Red X.
Test: Testing the significance of Red X, Risk
assessment
Understand: Understanding of interaction,
understanding relationship between Green Y and Red
X.
Apply: Application of solutions or actions,
procedure updated, Green Y monitoring.
Leverage: Lesson learned taken, benefits calculated.
Fig.2. Forged body showing inlet hole and leak off hole
There are about 30 techniques and tools which create
the comprehensive step-by-step system for process 2.1. Focus
improvement. When the defect come to organization first thing
which is done is transformation of business case into
technical project. Second step is making problem
2. DETAILS EXPERIMENTAL
definition tree.
Inlet hole and leak off hole are gun-drilled into a
forged body. It is horizontal drilling. At a time 4 bodies
are drilled with 80 second cycle time. Inlet hole and
leak off hole play important role inserting high
pressure fuel and removing the excess one. It happens
Project Statement: Find and eliminate the Red X
that many a times the hole remain half done or not driving inlet hole and leak off hole operation missing.
done.

Defect Event Feature Property

Fig.3. Problem definition

We have categorized the problem definition into

four different ways i.e. defect, event, feature and
property. According to it problem is a defect.

2.2 Approach

The effective utilization of the statistical tool and

quickness of the root cause identification relays on the
selection of samples with two extreme characteristics,
that is WOW (worst of worst) and BOB (best of best).
The type of problems that is tackled is apparently
limited to variation problems. The generic form of
2
 ROOT CAUSE ANALYSIS OF INLET HOLE AND LEAK OFF HOLE OPERATION MISSING PROBLEM IN CRI BODY USING SHAININ APPROACH

problems is a certain quality characteristic (which can

be a variable or an event) has a probability distribution
which does not meet the demands. Here the sample
which gives value close to mean is BOB and which is
towards either of the extremes is WOW.
To implement the process of elimination, SS uses
families of (causes of) variation and these families of
variation are created by Defect Strategy Approach. A
family of variation is a group of varying process inputs
that act at the same location or in the same time span.
Common families include within-part, part-to-part
(consecutive), time-to-time, location-to-location and
machine-to-machine.
Table 1: Family Variation

Fig.4. Solution tree

Primary step during converge process is to recheck

the measurement system based on which problem has
been formulated.

At any point in the search, the idea is to divide the

inputs remaining as possible dominant causes into
mutually exclusive families, and then to carry out an
investigation that will eliminate all but one family as
the home of the dominant cause.

2.2 Converge
Converging towards the RedX causing the GreenY
has been achieved by Component search technique.
The solution tree for the GreenY to determine the
RedX.
Fig.5. Isoplot
Discrimination ratio is greater than 6 hence we can
eliminate potential root cause in measurement. If we
look towards approach, there is large contrast in Time
to Time for same machine and also machine to
machine in same plant

No. of parts obtained

operation missing
15
10
5
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29

3
 ROOT CAUSE ANALYSIS OF INLET HOLE AND LEAK OFF HOLE OPERATION MISSING PROBLEM IN CRI BODY USING SHAININ APPROACH
Fig.6. Graph showing large contrast in time to time
It is seen that there is large contrast for time to time
and machine to machine
3. RESULTS AND DISCUSSION
3.1. Test
All the process parameters and machine
parameters were checked and machine was run. It was
seen that If there is no interruption no operation
missing parts are produced.
Fig.7. Control panel showing interruption
Fig.8. Solution Tree showing REDX
In case of tool broken there is separate poka-yoke
given for it such that after 120 cycle the machine gives
the alarm for change of drill. So tool breakage cases
are found less except if operator does not reset the tool
life.
3.2. Understand
With the help of reading and full factorial Experiment
we found out that tool blunt is contributing more than
coolant level low and tool breakage. It was seen that
4
after such interruption such machine get initialized and
such parts are carried forward.
Fig.9. Graph showing occurrence of REDX
CONCLUSIONS
Following conclusions have been drawn from the
experimental result and discussions.
1. Three RED X were found i.e. coolant level
low, tool broken and tool blunt
2. With the help of Full Factorial experiment
interaction between three RED X was found.
3. Shainin® has found to be simple and efficient
statistical tool which can give clue about the
most unsuspected design variation also
REFERENCES
[1] Bhaskara P1, Raghuveer Prasad2, “ROOT CAUSE ANALYSIS
OF CONTROL ROD FRICTION PROBLEM IN DFIP USING
SHAININ® APPROACH”, international journal of mechanical
engineering and technology, volume 5, 2014, pp.200-205
[2] Abhaysinh K, Desai, L.M. Jugulkar, “Process optimization by
using shainin six sigma tools and technique -case study in
manufacturing industry”, International journal of mechanical and
production engineering, Volume -2,April 2014 Date
[3] A.J.Jegadeesan, L. Karunamoorthy,"Investigation and
improvement in peak failure load of hot staked joints in starter
motor armatures using complementing problem - solving tools",
Journal of mechanical science and technology, volume 4, 2015,
1731-1736
[4] Clause Emmelmann,Juan Pablo Claderon, " Analysis of
Infuence of Burst -mode laser ablation by modern quality
tools",Science direct,Volume 12,2011,pp 172-181.
[5] R.B.Heboure,M.T. Telsong,"Casting defect reduction using
shainin tool in CI foundry - Case study and production
engineering, Volume 2, June 2014
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[6] Anand K. Bewoor*, Maruti S. Pawar,"Use of shainin tools for

simplifying six sigma implementation in QMS/ISO certified
environment - An India SME Case study", Journel of enginnering
Research and studies, E -ISSN, 0976-7916

Reference / Hand Books

[1] A.K. Verma, A. srividya , " Shainin method: edges over other
DOE technique",International Engineering management
conference,2004

[2] Jan Kosina, "Shainin Methodology: An Alternative or an

EffectiveComplement to
Six Sigma?" Quality innovative prosperity / KVALITA
INOVÁCIA PROSPERITA
2015

[3] Stefan H. Steiner and R. Jock MacKay," An Overview of the
Shainin SystemTM for Quality Improvement",

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