[PPT] - 1 QC STORY -32 QC STORY -32 QC STORY -32 QC Story-1 QC Story-1 PowerPoint Presentation

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On Behalf of

Susira Industries Ltd., Chennai. We Welcome the Delegates for the QCI – DL SHAH NATIONAL AWARDS ON ECONOMICS OF QUALITY

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FACTORY OVERVIEW

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SUSIRA INDUSTRIES LTD QC Story-1

Shop Floor view

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VISION

To be the number one manufacturer of quality engine valve push rods in the country and to become one among the top five by volumes in the international market. To expand the product portfolio by manufacturing other precision auto components/aggregates for national and international customers and increase the revenue four fold by 2015. To explore new frontiers of technology to meet the new and emerging market requirements. In the process, build a company deeply rooted in values and beyond profits; a culture of Quality, respect for the individual and an environment

f dependability and social responsibility – in short a company “built to

last”.

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SUSIRA INDUSTRIES LTD

India’s 1st SME to win 16 National awards for Quality and Business Excellence – Rajiv Gandhi National Quality Award for the year 1993 – ACMA Quality Award – 1994, 1998, 2000 – Golden Peacock National Award for total Quality - 1995 – NIQR-Bajaj ‘Outstanding Quality Man of the year’ - 1994 – ACMA Gold trophy for Export Excellence - 2005 – MMA Award for Managerial Excellence – 2005 – ACMA Certificate of Merit for Excellence in Technology –2007-08

CII Exim Bank Business Excellence award – Significant achievement commendation for the

year 2007-08

MSME award for ‘Outstanding Entrepreneur’ for the year 2007-08
ACMA award for Excellence in Quality and Productivity for the year 2008-09
Also won the 5S par excellent performance award (5 star performance award) from QCFI
Won the best QC story presentation by QCFI
Our team won the Outstanding and Excellent award in the 1st Poka yoke competition

conducted by QCFI

Our MD, Mr. Seetharamaiah was awarded the Life Time Achievement award from Ambattur

Industrial Estate Manufacturers' Association in the year 2010

Awards and Recognitions

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Certifications

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Customers - Domestic

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Customers - International

Cummins Inc. (USA, UK, Brazil, China & Mexico) Scania, Sweden SAME Deutz-Fahr Group S.P.A., Italy Iveco, Italy

John Deere, USA

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Customers - Prospective

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Products

Valve seat Inserts Push rod Tappets Piston Cooling Nozzle 12

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Presentation on

Reduction in Manufacturing cost achieved in Induction Hardening

peration through break through

machine design Improvement.

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INTRODUCTION

SGA Name : PASSION Work Area : Induction Hardening Members : G.Ganesan – Metallurgy R.Sivanesaselvan - Maintenance P.Dillibabu - Production P.V.Ganesan - Production Meeting Schedule

: Every Monday 2.00pm

Facilitator :

B. Monikandan

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PLAN DO CHECK ACT

1 4 3 2

Methodology

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SGA-QA-26

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1. Cup Offset
2. Quenching Crack
3. Control Length Under size
4. Low productivity in Induction Hardening
5. Ball Flat Over Size

List of Problems Identified

P L A N

Tool : BRAINSTORMING

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List of Problems Identified - Contd

P L A N

Tool : BRAINSTORMING

6. Total Run out high in Cummins push rod
7. Cup ID Black spot
8. Cup ID pit marks
9. Low Hardness
10. Total Length Under size

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11. Gap between Ball and Cup
12. Cup OD Tool Mark
13. Low Weld Strength
14. Less yield in 961 Push Rod
15. Induction Hardening Cost High
16. Induction Hardening Through Put time high

P L A N

Tool : BRAINSTORMING List of Problems Identified - Contd

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CATEGORISATION OF PROBLEMS

Category Description A Minimum involvement of other departments in solving them B Involvement of other department is necessary C Management approval and support needed

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L A N

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P L A N

Categorization of problems A Category Problems

1. Cup Offset 2. Quenching Crack 3. Control Length Under size 4. Ball Flat Over Size 5. Total Run out high in Assembled Push Rod 6. Cup ID Black Spot

7. Cup ID Pit marks
8. Low Hardness
9. Total Length U/s
10. Cup OD Tool Mark
11. Gap between Cup and Ball
12. Low Weld Strength

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P L A N

Categorization of problems B Category Problems

1. Low productivity in Induction Hardening. 2. Less Yield in 961 Push rod QC STORY -32

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P L A N

Categorization of problems C Category Problems

1. Induction hardening Through put time high 2. Induction Hardening Cost High QC STORY -32

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GUIDE LINES FOR RANKING

Effect on customer Effect on productivity Effect on Cost Effect on delivery

Note: Higher the severity lower the rank

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RANKING METHODLOGY

Score - 1

Very High Severity

Score - 2

High Severity

Score - 3

Medium Severity

Score- 4

Low Severity

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Effect at Customer Effect of Productivit y Effect of Cost Effect of Delay in delivery Total Score Ranking 1 Cup Offset 1.0 1.0 2.0 1.0 5.0 2.0 2 Quanch Crack 1.0 2.0 3.0 3.0 9.0 6.0 3 C/L U/s 1.0 3.0 2.0 2.0 8.0 5.0 4 Low Productivity in Induction Hardening 1.0 1.0 1.0 1.0 4.0 1.0 5 Ball Flat O/S 1.0 3.0 3.0 3.0 10.0 7.0 6 Total Run out high in Cummins push rod ( 100%) 1.0 2.0 1.0 2.0 6.0 3.0 7 Cup Id Black spot 3.0 3.0 3.0 4.0 13.0 8.0 8 Cup ID pit marks 3.0 4.0 4.0 4.0 15.0 10.0 9 Low Hardness 1.0 3.0 3.0 3.0 10.0 5.0 10 Total Length U/s 1.0 3.0 2.0 2.0 8.0 4.0 11 Gap Between Cup & Ball 1.0 2.0 2.0 2.0 7.0 4.0 12 Cup OD Tool Mark 1.0 1.0 2.0 3.0 7.0 4.0 13 Low weld strength 1.0 2.0 3.0 3.0 9.0 4.0 LIST OF QUALITY PROBLEMS SL# DEFECT RANKING

Selection of problem through ranking

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MILE STONE CHART

To increase Productivity in I/H Machine SGA-QA-32 Monday Oct 6- 11 Oct 13-18 Oct 20- 25 Oct 27- 31 Nov 3- 8 Nov 10-15 Nov 17-22 Nov 24-29 Dec 1-6 Dec 8- 13 Dec 15-20 P A P A P A P A P A P A P A p A P A P A P A CHEC K 8 10 Cause-effect analysis DO 6 7 PLAN Root cause analysis Data analysis on the Root cause Identification of Problem(which are unsolved) SL# STEPS Planned Date

f

Completion No of Projects Follow up/Review and recurrence prevention 11 Trial implementation & checking performance 9 Regular implementatio Development of solution Manufaturing Cost Increase 31.12.08 25 Selection of problem Definition of the problem Analysis of problem Project on Project No Meeting Day Reason for Selection Started on Time ACT 06.10.08 2.0 - 3.0 PM 1 2 3 4 5 WEEK year -2008 PDCA

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Process Flow Diagram

Incoming material inspection Bar shearing and Cup end Forging Ball end Forging CNC Machining Induction Hardening Tempering Inspection & Packing SUSIRA INDUSTRIES LTD

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Current situation

69

72 71 31 28 29

10 20 30 40 50 60 70 80 July'08 Aug'08 Sep'08

Month

% of Production

Subcontract Production In-house Production

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Current situation

3.9 4.0 3.8 3.2

0.5 1 1.5 2 2.5 3 3.5 4 4.5 Jun'08 July'08 Aug'08 Sep'08

Month

Value in Lakh

In-house Production

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ANALYSIS OF PROBLEM

Through 4W & 1H

WHAT - Low Productivity in I/H WHEN - Induction Hardening Operation WHERE - Induction Hardening Machine WHO - Passion Team HOW - By Systematic Analysis & causes

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Analysis

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BRAINSTROMING POINTS

P L A N

Low Productivity in Induction Hardening machine due to:

1. Heating Time High
12. Process Time high
2. Quenching time high
3. Unskilled operator
4. Heating Coil design to be changed
5. Machine Design
6. Insufficient power source
7. I/H cost high at subcontracting
8. Single end hardening
9. Loading time & Unloading time high

10.Quenching coil diameter more 11.Low feed rate QC STORY -32

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Analysis Through – Cause & Effect diagram
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VALIDATION
Significant Cause

1.1 1.1

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2.1

2.3 2.2 2.1

VALIDATION

2.4
2.2
2.3
2.4

Significant Cause Significant Cause Insignificant Cause Insignificant Cause QC STORY -32

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3.1

3.3 3.2 3.1

VALIDATION

3.5

Significant Cause

3.4

3.6

3.2
Insignificant Cause

3.3

Insignificant Cause

3.4

Insignificant Cause

3.5

Significant Cause

3.6

Insignificant Cause

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ANALYSIS OF PROBABLE CAUSES
4.1

Insignificant Cause

4.1

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Vital Causes Action Plan Action Plan Action Plan Vital Causes

Less production (800 Nos) per shift at supplier end Machine Design Single end Hardening

Problem

Loading and Unloading Time

high Cycle time high

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Development Of Solution

Less production at supplier end Cycle time high Single end I/H

WHY?

WHY? SOLUTION

1.1

Machine designed with single end Induction hardening facility Machine to be modified with double end induction hardening and additional features to reduce cycle time

PROBLEM – Low productivity in Induction Hardening

WHY?

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Development Of Solution

Machine Design No provision for double end Machine is designed for single end

SOLUTION

2.1

Standard machine available with the manufacturer/market

WHY? WHY? WHY?

Machine to be modified with double end induction hardening and additional features to reduce cycle time

PROBLEM – Low productivity in Induction Hardening

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Development Of Solution

Single end

SOLUTION

2.1

Standard machine available with the manufacturer/market

WHY? WHY? WHY?

Machine to be modified with double end induction hardening and additional features to reduce cycle time No provision for double end Machine designed with single end facility

PROBLEM – Low productivity in Induction Hardening

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Development Of Solution

Loading and Unloading Time High

SOLUTION

2.1

Standard machine available with the manufacturer/market

WHY? WHY? WHY?

Machine to be modified with double end induction hardening and additional features to reduce cycle time loading one at a time Machine designed with single end facility

PROBLEM – Low productivity in Induction Hardening

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Development Of Solution

Cycle Time High

SOLUTION

2.1

Standard machine available with the manufacturer/market

WHY? WHY? WHY?

Machine to be modified with double end induction hardening and additional features to reduce cycle time Single end Hardening & loading one at a time Machine designed with single end facility

PROBLEM – Low productivity in Induction Hardening

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SI. No. Solution Action to be Taken Responsibility & Target Status

Action Plan

1 Machine to be modified with double end induction hardening and additional features to reduce cycle time 1) Additional features for the new machine to be identified by CFT

CFT

Development Of Solutions

2) New machine design with improved features such as conveyer type , drop quench, Channel type coil. will be finalized jointly with the machine manufacturer and action will be initiated for procurement.

CFT

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INTRODUCTION

CFT

B.Monikandan

QA

G.Ganesan

Metallurgy

R.Sivanesaselvan - Maintenance P.Dillibabu

Production

P.V.Ganesan

Production

P.Muthaiah – HF Technologies(Machine Supplier) S.Kruppaiah – HF Technologies(Machine supplier)

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1. Double end Induction Hardening done simultaneously 2. Horizontal loading 3. Continues feeding 4. Conveyer type 5. Drop quenching 6. Cone type Coil 7. Polymer quenching

Tool : BRAINSTORMING TO DESIGN THE NEW MACHINE

8. Poke Yoke system
9. Required power source
10. Adjustable Feed rate control

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IMPROVED FEATURES IN THE NEW MACHINE

Both ends to be simultaneously Induction

Hardened.

Continuous feeding with adjustable feed rate. Drop quenching. Poka yoke system for power drop , power

failure and heating station trip.

Independent heating control for cup & ball end

induction hardening.

Cycle time – the above features leading to

reduce cycle time.

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Machine Front View SUSIRA INDUSTRIES LTD

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Poka -yoke sensor to ensure correct orientation of push rod while loading

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Conveyor Loading of the part

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Poka yoke system ( pneumatic device ) for holding the components during power drop or power failure or heating station trip

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Poka yoke system ( pneumatic device ) for holding the components during power drop or power failure or heating station trip

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Stopper to avoid sudden fall in to the Quenching Tank

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Cone Type Coil for Cup end Channel Type Coil for Ball end

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Quenched Components are taken out through the collector which is placed in the Quenching tank.

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QUENCH

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Validation

Various trials conducted and suitable Setting Parameters established for Regular Production and machine output is found to be consistently meeting the product specification requirements. Product Quality of the product depends on 3 variables

1.

Feed rate

2.

Power

3.

Polymer Concentration.

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Sl# Trial Side Voltage Tab Feed rate Crack Test Hardness Specification Hardness Observed in HRC Case Depth Spec. Observed Case Depth Mould No Micro Structure Result 1 Trial - 1 139 Cup 80 2&5 32 Ok 55 - 60 58 - 59 Min 15.0mm 17.0 mm 2976 Mainly Martensite with few retained austenite Accepted 2 Trial - 2 139 Cup 80 2&5 33 Ok 55 - 60 58 - 59 Min 15.0mm 16.50 mm 2977 Mainly Martensite with few retained austenite Accepted 3 Trial - 3 139 Cup 80 2&5 32 Ok 55 - 60 58 - 59 Min 15.0mm 17.0 mm 2979 Mainly Martensite with few retained austenite Accepted 4 Trial - 4 139 Cup 80 2&5 33 Ok 55 - 60 57 - 58 Min 15.0mm 16.50 mm 2980 Mainly Martensite with few retained austenite Accepted 5 Trial - 5 139 Cup 80 2&5 33 Ok 55 - 60 57 - 59 Min 15.0mm 16.50 mm 2980 Mainly Martensite with few retained austenite Accepted

HF INDUCTION HARDENING MACHINE VALIDATION REPORT - CUP

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Sl# Trial Side Voltage Tab Feed rate Crac k Test Hardness Specificatio n Hardness Observed in HRC Case Depth Spec. Observe d Case Depth Mould No Micro Structure Result 1 Trial - 1 139 Ball 80 2&5 32 Ok 55 - 60 57 - 59 Min 15.0m m 16.50 mm 2976 Mainly Martensite with few retained austenite Accepted 2 Trial - 2 139 Ball 80 2&5 33 Ok 55 - 60 57- 59 Min 15.0m m 16.50 mm 2977 Mainly Martensite with few retained austenite Accepted 3 Trial - 3 139 Ball 80 2&5 32 Ok 55 - 60 57 - 59 Min 15.0m m 17.0 mm 2979 Mainly Martensite with few retained austenite Accepted 4 Trial - 4 139 Ball 80 2&5 33 Ok 55 - 60 57 - 58 Min 15.0m m 16.50 mm 2980 Mainly Martensite with few retained austenite Accepted 5 Trial - 5 139 Ball 80 2&5 33 Ok 55 - 60 57 - 59 Min 15.0m m 16.50 mm 2980 Mainly Martensite with few retained austenite Accepted

HF INDUCTION HARDENING MACHINE VALIDATION REPORT - BALL

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Action Plan Action Plan Action Plan Comparative study

Before After

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Action Plan Action Plan Action Plan Comparative study

Before After

Cycle time 48 Sec/1 no ( In-house ) &

36 Sec/ 1 no ( Subcontractor )

In house 600 Nos Induction hardening

per shift.

Subcontractor end 800 Nos per shift
Components Induction hardening cost

Rs.4.00/no (In house) Rs.3.75/no(sub)

Monthly total production in house and

subcontractor 72800 Nos

Cycle time 9.3 Sec/ 1no
In house 3100 Nos Induction

hardening per shift

In house 3100 Nos Induction

hardening per shift

Component Induction hardening

cost Rs.0.97/per no

Monthly total production in house

161200 Nos. Customer schedule 100% achieved with in house facility QC STORY -32

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Comparative Graph for results obtained

Production in Induction Hardening machine

69 72 71 76 71 74 81 83 95 100 100

10 20 30 40 50 60 70 80 90 100 J u l ' 8 A u g ' 8 S e p ' 8 O c t ' 8 N

v

' 8 D e c ' 8 J a n ' 9 F e b ' 9 M a r ' 9 A p r ' 9 M a y ' 9

Month

% of Production

In house Production Supplier Production

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Current situation

3.9

4.0 3.8 3.2 3.4 3.1 3.4 2.4 0.76 0.35 0.35 0.35

0.5 1 1.5 2 2.5 3 3.5 4 4.5 J u n ' 8 J u l y ' 8 A u g ' 8 S e p ' 8 O c t ' 8 N

v

' 8 D e c ' 8 J a n ' 9 F e b ' 9 M a r ' 9 A p r ' 9 M a y ' 9

Month

Value in Lakh

In-house Production

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QC Story-1 MILE STONE CHART

To increase producivity in I/H SGA-QA-32 Monday Oct 6- 11 Oct 13-18 Oct 20- 25 Oct 27- 31 Nov 3- 8 Nov 10-15 Nov 17-22 Nov 24-29 Dec 1-6 Dec 8- 13 Dec 15-20 Jan 1 - 30 Feb 1 - 28 P A P A P A P A P A P A P A p A P A P A P A Follow up/Review and recurrence prevention 11 Trial implementation & checking performance 9 Regular implementatio 10 Development of solution 8 Selection of problem Definition of the problem Analysis of problem Cause-effect analysis Root cause analysis Data analysis on the Root cause 7 Date of Completion No of Projects WEEK year -2008 Reason for Selection Started on Time 26.02.2009 25 Manufaturing Cost Increase Project on Project No Meeting Day PDCA SL# Identification of Problem(which are unsolved) PLAN 5 STEPS CHEC K ACT 06.10.08 2.0 - 3.0 PM 1 2 3 4 DO 6

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Action Plan Action Plan Action Plan

1.

Productivity Increased from 1200 nos to 6200 nos Per day 2. Push rod for Induction hardening Cost Rs.3.03 per push rod saved 3.

Rs. 227419.00 per month saving

4. Rs .27,29,032.00 per year saving 5. Subcontracting totally eliminated.

Rs 27,29,032.00 per year

1. This Machine is a concept machine jointly developed by our

in house talent and with machine manufacturer expertise and their co-operation. This costed us Rs. 11 lakhs.

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Action Plan Action Plan Action Plan

1. Through put time reduced.
2. Enhanced on time delivery.
3. Increased Customer satisfaction.
4. Operator morale improved.

STANDARDISATION: The PPAP documents - Process Flow diagram ,PFMEA Control Plan & SOPs have been amended.

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Horizontal Deployment

1. Double end introduced in

Scanner Induction Hardening machine.

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2. New Induction hardening

machine procured with the same concept and spray quench simultaneously QC Story-1

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TOOLS USED

1. Brain Storming
2. Data Collection
3. Flow Chart
4. Cause & Effect Diagram
5. Bar charts

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