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QM

Micro Turners Pantnagar


QM Pillar Activity
Presentation By
S K Verma
Date : 19th March-2011
MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

CONTENTS
TOPICS

S. NO.

QM
SLIDE NO.

Background

Aim

Structure- QM Pillar

Targets

Scope

Activities on Customer Complaints - Warranty

08-19

Activities on Customer Complaints - EFR

20-28

Activities on Customer Complaints

29-50

Activities on In-process Rejection

51-69

10

Future Plan

MICRO TURNERS PANTNAGAR

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TPM - The Prime Mover Towards Excellence

BACKGROUND

QM

In-house Rejection

Warranty Rejection
WHY
QM ?

Inspection standard
not adequate

MICRO TURNERS PANTNAGAR

Customer Complaint

Reactive Approach

TPM - The Prime Mover Towards Excellence

Aim- QM Pillar

QM

To establish defect free manufacturing process, where quality is


built into process, leading to consistent product performance and
quality into the hands of customer.

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM Pillar - STRUCTURE

QM

SK Verma
(PILLAR CHAIRMAN)

Mr. Praveen Kumar


( Machine Shop )

Mr. Sanjay
Verma

Mr.
Surender
Kumar

MICRO TURNERS PANTNAGAR

Mr. RN Singh
( Machine Shop )

Mr. VK
Singh

Mr. Gaurav
Tyagi

Mr. DD Giri
( HT & Plating )

Mr. Ajoy
Mukharji

TPM - The Prime Mover Towards Excellence

Mr. Manoj
Bangali

QM-Targets

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

QM SCOPE

QM

QM ACTIVITY

Customer complaint
prevention
activities

In process
defect
prevention
activities

Vendor component
defect prevention
activities

Warranty

M/c Shop

Bought out
Components

EFR

Heat
treatment

Job Work

Customer
Complaint
s

plating

In house

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

Total warranty claims received till date from 6 to 24


months
of Vehicles sold month or 30,000 kms, whichever is
earlier.

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

WARRANTY
Warranty Claims Analysis
Flow

QM

Receipt of field parts /


Report from field

Analysis by CFT
members of all
interfacing function
Action identification

Manufacturing
related

Non
conformance
(NC to drawing
specification)

MICRO TURNERS PANTNAGAR

Design related

Basic
Design
Error

Robustness
to support
Mfg. &
Service

Field related

Periodic
maintenanc
e issues

TPM - The Prime Mover Towards Excellence

Usage
issues

WARRANTY
Non Conformance
(NC to drawing
specification)
Analysis

Manufacturing related

Can detect

Make it detectable

Inspection Side
Inspectio
n Poka

Inspection
Plan
inadequate

Cause Side

Difference
in
standards

Inspection
Method wrong

Daily Check
List

MICRO

Feedback

Feedback

Update PQCP
Update PRBFM
Update Check sheets
TPM
Update
Inspection agreement
TURNERS
PANTNAGAR

Material
nonconformanc
e

Establish cause source


through QA matrix
Identify 4M & T
conditions
Kaizen for maintaining
4M & T conditions Sustenanc

Identify further possibilities & countermeasure

Feedback

Surface
coating
nonconformanc
e

Dimensional
nonconformance

Update Change/ Communize with reference


Inspection
to respective
Plan

Feedback

Cannot detect

Cause Side

Inspection
Plan

Poka
Yoke

QM

e
Machine
PM &
JH

Material
PPC &
QM

Method
KK, JH &
PM

- The Prime Mover Towards Excellence

Men

Tool

E&T &
QM

KK &
PM

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WARRANTY

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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WARRANTY

QM

DEFECT PHENOMENA MATRIX

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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WARRANTY

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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WARRANTY

QM

DEFECT PHENOMENA MATRIX

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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WARRANTY
ANALYSIS
&ACTION

Part name
Model:
Phenomena

QM

: Shaft Kick
: All Model
: Crack / Broken

Probable Causes

Actions

Material Property 16MnCr5

Checked & found - OK

Surface Hardness 77/81


HRA

Checked & found OK ( 79/80


HRA )

Core Hardness 25/45 HRC

Checked & found OK ( 38 HRC )

Case depth 0.10/0.30 mm

Checked & found OK ( 0.30 mm )

5.

Plating Process Hydrogen


de-embrittle ment treatment
not done / not done
properly .

Ensure 100% Hydrogen deembrittle ment treatment in


Plating.

6.

Weak Design

Design has Changed by BAL


(Radius 3.5 to 4.2 mm & Dia 10
mm to 11.5 mm )

Sr.
no.

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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WARRANTY

QM

Action
Action: :Ensure
Ensure100
100%%Hydrogen
Hydrogende-embrittlement
de-embrittlementTreatment
Treatmentduring
duringPlating
Plating
MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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WARRANTY

QM

IMPROVEMENT SHEET
Problem/Status:- Crack / Broken

Date of Implementation :- July- 2010

BEFORE

AFTER

Probable Cause:-

Counter Measure:-

-Weak Design.

1.

Radius 3.5 mm change to 4.2


mm

2.

Diameter 10 mm change to 11.5


mm

Idea:-

Change Design

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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WARRANTY RESULTS

Action
ActionTaken
Taken
July,10
July,10

QM

G
O
O
D

Old
OldPart
Part
Manufactured
Manufactured
ininmarch,10
march,10

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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WARRANTY

QM

Interaction with CQA BAL Akurdi for


Interaction with
CQA BAL Akurdi
for
understanding
& corrective
actions
understanding & corrective actions

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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QM

Warranty claims received in less then 6 months


of Vehicles sold or less then 3000kms, whichever is earlier.

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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EARLY FAILURE

AS per SAP data


AS per SAP data

MICRO TURNERS PANTNAGAR

As per Mfg. NC
As per Mfg. NC

TPM - The Prime Mover Towards Excellence

QM

G
G
O
O
O
O
D
D

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EARLY FAILURE DEFECT PHENOMENA


MATRIX

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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EARLY FAILURE

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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EFR (DEFECT PHENOMENA


MATRIX)

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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ANALYSIS & ACTION - NOISY

QM

Noisy

Drive Assembly

Total Composite Tooth to Tooth


Error 0.10
Error 0.03

OK
OK
1.
2.
3.

Gear Starter Clutch

Tooth Profile
Error More

OK
OK

OK
OK

First Pc Inspection & Confirmed


In- Process 2/250 pcs Inspection.
Final Stage 100 % Inspection
1.
2.

MICRO TURNERS PANTNAGAR

Total Composite Tooth to Tooth


Error 0.10
Error 0.03

OK
OK
1.
2.
3.

Tooth Profile
Error More

OK
OK

First Pc Inspection & Confirmed


In- Process 2/250 pcs Inspection.
Final Stage 100 % Inspection

KAIZEN

First Pc Inspection & Confirmed


In- Process 1/1000 pcs Inspection.

TPM - The Prime Mover Towards Excellence

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ACTIONS ON NOISY Gear Starter clutch

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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EFR RESULTS

New
NewParts
Parts
Supply
Started
Supply Started

QM

GG
OO
OO
DD
Action
Action
Taken
Taken

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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WARRANTY

QM

Interaction with CQA BAL Akurdi for


Interaction with
CQA BAL Akurdi
for
understanding
& corrective
actions
understanding & corrective actions

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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QM

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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CUSTOMER COMPLAINT APPROACH

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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CUSTOMER COMPLAINT

QM

1.1. BAL
BALQ
QBronze
BronzeAwardAward-Oct,
Oct,2008
2008
2.2. BAL
Q
Silver
AwardApr,2009
BAL Q Silver Award- Apr,2009
3.3. BAL
BALQ
QGold
GoldAwardAward-QualifiedQualified-Apr,2010
Apr,2010
New
NewParts
PartsSupply
Supplystarted
started

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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CUSTOMER COMPLAINT

QM

DEFECT PHENOMENA MONITORING

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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CUSTOMER COMPLAINT

QM

ANALYSIS & ACTIONS

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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CUSTOMER COMPLAINT

QM

ANALYSIS & ACTIONS

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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ACTION ON STEP AT DIA. IN DRIVE


ASSLY.

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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CUSTOMER COMPLAINT

QM

IMPROVEMENT SHEET
Problem/Status:- Step on Dia. In Drive Assly

Date of Implementation :- 10.10.10

BEFORE

AFTER

Root Cause:-No mechanism for locking the Horizontal slide.

Counter Measure:- Plate & Bolt is attached with Machine to lock the
Horizontal Slide

Idea:- TO Make a provision to lock the Horizontal Slide

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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CUSTOMER COMPLAINT

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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CUSTOMER COMPLAINT

QM

IMPROVEMENT SHEET
Problem/Status:- Total length Over size Bearing

Date of Implementation :- 18.11.2010

Race
BEFORE

AFTER

INSPECTION BY MICROMETER DURING SETTING

INSPECTION BY SNAP GAUGE DURING SETTING

Root Cause:-

Counter Measure:- Snap Gauge is provided on machine to avoid checking

- During setting Error in reading of Micrometer.

error.

Idea:- TO eliminate Inspection checking Error.

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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Zero Customer Complaint Sustenance

QM

Zero Customer Complaint Sustained By:1. Counter-measures on components arrested at Final inspection
stage.
2. PDI operator recognition
3. Q Methodology Implementation.

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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Zero Customer Complaint Sustenance

QM

1. Counter-measures on components arrested at PDI.


Daily defect monitoring sheet

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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Zero Customer Complaint Sustenance

QM

3. PDI operator recognition

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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Sustenance for Zero In-Process Defect

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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Sustenance for Zero In-Process Defect

QM

Component Study

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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Sustenance for Zero In-Process Defect

QM

Critical dimension identification

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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Sustenance for Zero In-Process Defect

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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Sustenance for Zero In-Process Defect

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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Sustenance for Zero In-Process Defect

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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Sustenance for Zero In-Process Defect

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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Sustenance for Zero In-Process Defect

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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Sustenance for Zero In-Process Defect

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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QM

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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IN-HOUSE REJECTION

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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IN-HOUSE REJECTION

QM

GOOD

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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IN-HOUSE REJECTION

QM

PROCESS WISE PPM & DEFECT PHENOMENA


2010-11

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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IN-HOUSE REJECTION

QM

DEFECT PHENOMENA MATRIX FOR FIRST TWO HIGH VALUE


REJECTION COST

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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IN-HOUSE REJECTION

QM

ANALYSIS & ACTIONS

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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IN-HOUSE REJECTION

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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IN-HOUSE REJECTION

MICRO TURNERS PANTNAGAR

Kaizen

TPM - The Prime Mover Towards Excellence

QM

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IN-HOUSE REJECTION

MICRO TURNERS PANTNAGAR

-Kaizen (Plating)

TPM - The Prime Mover Towards Excellence

QM

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IN-HOUSE REJECTION

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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IN-HOUSE REJECTION

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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IN-HOUSE REJECTION

QM

ANALYSIS & ACTIONS - Sprocket

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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IN-HOUSE REJECTION

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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IN-HOUSE REJECTION

QM

Defect
DefectPhenomena
Phenomena- -88nos.
nos.

HappenedHappened-22
Kaizen
Kaizen
- -22

PokaPoka- In-process
In-process
Yoke
Inspection
Yoke
Inspection

MICRO TURNERS PANTNAGAR

May
MayHappen
Happen- -66

Kaizen
Kaizen

PokaPokaYoke
Yoke

TPM - The Prime Mover Towards Excellence

In-process
In-process
Inspection
Inspection- -66

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IN-HOUSE REJECTION

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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IN-HOUSE REJECTION

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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IN-HOUSE REJECTION

QM

RESULTS SPROCKET CELL

All
AllActions
ActionsCompleted
Completed

Results
Results
GG
OO
OO
DD

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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IN-HOUSE REJECTION

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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IN-HOUSE REJECTION

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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FUTURE PLAN

MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

QM

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QM

THANK
YOU
MICRO TURNERS PANTNAGAR

TPM - The Prime Mover Towards Excellence

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