Copy of Hoshin KanrDec2013 (1)

8/10/2019 Copy of Hoshin KanrDec2013 (1)

1/19

CE Engineerings and Chemicals Pvt

Ltd

SIA ACTIVITY

Dec13


2/19

SIA Monthly Review PPT

Signed Hoshin KanriCo-operation Team Supplier Improvement Activity Plan in ACE Engineering

Quality Goal VECV Team Supplier Team

# To reduce ppm level to 150 PPM by

2014 end

Facilitator Mr Tomochi Katsumata MD & CEO Mr. Pradeep Jain

Leader Mr Vinayak Shanbagh Head-Manuf. Mr. Manoj Ohja

#

Zero defect at customer end

Co-ordinator Mr Yogesh Jagtap Head-Design Mr. Ramkaran Meena

Materials Mr Jeetendra Joshi RQC Mr. Mayur Ajmera#

Continual improvement in process

through Poka-Yoke & Kaizens

QA Ms. Neha Jain In process Quality Mr. Mayur Ajmera

PDD Mr. Amarjeet singh PDI Mr. Mayur Ajmera

Supplier up-gradation Mr. Vinay Singh Tool Room Mr. Rajesh Dixit

Main

Issu

e

Controlled KPI -Ace Engg.

Activity

Watched KPI - Ace Engg. Responsible &

Supporting DepartmentObje

ctive

Name

KPI

Item

s

2009

(Base)

201

2

Tgt. Tgt.

Respons

ibleKPI Items

Base

(2012

Q4)

Target 2013

Respo

nsible2013 2014 Q1 Q2 Q3 Q4 ProdDesig

n

Tool

room

QCpurch

ase

Delivery

Qual

ity

PPM

wise

PPM

Impr

ove

ment

Delivery

PPM

impr

ove

ment

11575 350 200 150 CFT

Start

QRQCIn-house monthly PDI PPM 3747 3000 2500 200 1500

CalibrationIn-house monthly Process

PPM4000 3800 3500 3200 3000

MSA In-coming monthly PPM 1950 1800 1700 1600 1500

5SNo of DOL parts

(Total 68 parts)61 62 63 65 66

ProcessAudit

PDI Execution (% of PDI

followed invoices/Totalinvoices raised)

100 100 100 100 100

Poka Yoke Process audit (No of parts ) 8 3 3 3 3

Layout inspection (No. of

parts)10221 29 19 18

IMTE and Gauge Calibration - - - 8

Tooling validation (Dies, Jigs

& Fixture validation &

Maintenance)

10 0 5 5 5

Poka Yoke 12 3 5 6 6 QS Sign off _ _ 40 28

System audit score 81% 95%


3/19


ACE ENGINEERINGS & CHEMICALS PVT.LTD.

Monthly Internal Hoshin Kanri Review MOM with top management

S.

No

.

Date Location Issue Analysis Action Target Dt. Complet

ion Dt

Resp. GY

R

stat

us

1 5/12/13 VECV

Cover plate

assy

rejection

Due to improper adhesiveness of

insert on pp part cover plate assy.

Insert comes out; the adhesive

used acra-bond shows poor

compatibility with the partmaterial.

Adhesive My-T Bond grade

103 is used & tested as per

pull out test.

7/12/13 7/12/13

2 12/12/13 VECV

GSC IA303087- C.C

Dimension is

out by 9-10-

mm due to

which fitment

issue

occurred.

Rejected mould were used byproduction dept, only 2 mould were

OK and rest were rejected due to

which ok & not ok parts were found at

VECV as well as FG Stock. Drilling

done by seeing marking which is very

light due to which c.c varies is also the

source of variation.

Each part checked at

FG,filing,painting,moulding,re

worked with providion of

drilling fixture. New mould to

be provided with pin provision

for further production.

17/12/13 17/12/13Mr.Laxman

Surage


4/19


ACE ENGINEERINGS & CHEMICALS PVT.LTD.

Monthly Internal Hoshin Kanri Review MOM with top management

S.

No

.

Date Location Issue Analysis Action Target

Dt.

Complet

ion Dt

Resp. GYR

status

3 22/12/13 vecvGear shift cvr

IA209914 gap

issue.

It is seen that the gap of 15-25 mm

found after fitment of the part on

line. When checked dimensionally

height found 409-415 mm against 412

mm. Although part as per drawing has

also resulted in gap from chamfer

side.

Sample (3) provided to VECV as

per fitment basis. Waiting for

feedback for changes from

VECV.

5/1/14 TBP vecv


5/19


Control KPI

KPI Summary

Months Jan-13 Feb-13March-

13Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13

KPI R Y G R Y G R Y G R Y G R Y G R Y G R Y G R Y G R Y G R Y G R Y G R Y G

Controlle

d0 0 1 1 0 0 0 0 1 0 0 1 1 0 0 0 0 1 1 0 0 0 0 1 0 0 1 0 0 1 1 0 0 0 0 1

Controlled KPI :-

S. No.Main

Issue

Objective

NameKPI Items Status

Targets VS ActualRemark

s13-

Jan

13-

Feb

13-

Mar

13-

Apr

13-

May

13-

Jun13-Jul

13-

Aug

13-

Sep

13-

Oct

13-

Nov

13-

Dec

1.

Delivery

Quality

PPM

wise

PPM

Improveme

nt

Delivery PPM

improvement

TARGET 325 325 325 300 300 300 250 250 250 200 200 200

ACTUAL 49 939 96 39 606 0 756 200 90 79 682 133


6/19


Control KPI 1 Pareto & Root Cause analysis with implementation detail

1 1 1

7

9

10

0

2

4

6

8

10

12

Handle Loose Metal Insert

removing

Hinge Inclined DAMAGE BOLT LOOSE PAINT PROBLEM

DEFECT REPEATATION

QUANTITY


7/19

Customer End Rejection Monitoring from JAN '13-DEC 13

Sno.Item

CodeItem Name Nature of Defects

JAN'13

FEB'13

MAR'13

APR13

MAY'13

JUN'13

JUL'13

AUG'13

SEP'13

OCT'13

NOV'13

Dec;13

Root Cause Action PlanTarget

Date

Statu

s

(RY

G)

1 IA22025

9

PANEL SHIELD

SIDE UPPER RH

DAMAGE 1 NA NA NAG

2 IA22453

5

ASSY. ENGINE

COVER

BOLT LOOSE 9 Pin dia was less in

mold.

Mold scraped which was

found wrong

02-Mar-

13 G

100% of visual inspection

will be done of the bolt

before dispatch & yellow

sticker is pasted on the hinge

if bolt found wrong

01-Mar-

13

G

HANDLE 1 I1)mproper tightening

of the screw

1)Sop prepared for

tightening the screwControl; plan has also been

revised.

2) Checking of handle by

pulling it is also implemented

at the time of PDI

01-Nov-

13

G

3 IA225381

PAD SPRAYSUPPRESSION

CD DIMENSIONNOT OK

3 Drilling fixture verified& found not ok

New drilling fixture madewith hardened bush.

Checking of gauges is done in

every 4 month.

15-Feb-12

G

7 Drilling process is not

adequate .

Punching will be used for the

control of dimension

8/06/13

G

4

IA22360

9

BATTERY COVER

DAMAGE(AIR

BUBBLE AROUND

BUSH

1Air bubble at the time

of molding

Painting process has been

revised , checking being done

at primer stage.

25

may13

g


8/19


Sno

.

Item

CodeItem Name Nature of Defects

JAN'13

FEB'13

MAR'13

APR13

MAY'13

JUN'13

JUL'13

AUG'13

SEP'13

OCT'13

NOV'13

Dec;13

Root Cause Action PlanTarget

Date

Statu

s

(RY

G)

5IA30745

2

AIR CLEANER

COVER ASSY

DAMAGE 2 G

DAMAGE AT

GROMMET2

Crack found at the position of

grommet

Grommet will beassemble in parts at

supplier end

G

2

Previously grommet was fixed

by hand , due to

transportation there are

chances of releasing grommet

from parts.

At the time of fixing the

grommet , the adhesive

is also pasted to give

good bonding.

10/08/20

13

G

6IA23018

7

COWL GRILL

CENTER (HCV

FACE COWL)

DAMAGE 1 Handling damage at VECV -- NIL G

C.C OUT

1

Different parts were checked

dimensionally with logo

fitment and found ok at

VECV by our quality person.

It is to be discussed with

the VECV concern

erson that part

rovided is ok but the

mating part could not

meet the dimension.

Sep13 G

C.C OUT 1

It is analyzed that C.C 280 is

observed 277-278mm.While

mounting the logo taking hole

as reference the last pin (215

C.C in part)is coming out of

the part when logo is fitted.

Logo pin also has variation of1 mm in C.C dimension.

Part, tool & mating part

dimensions measured for

rectifying the tool. Tool

sent to tool maker for

modification in c.d of pin

location.0/10/201

3

G

The 2 mm variation in part &

1 mm variation in logo

resulted in problem

Parts provided by filing

the slots as an immediate

action.

7IA22999

0COWL GARNISH

LOGO FITMENT

ISSUE

3

Observed that horse logo

resent at VECV is not fitted

and logo at our end has no

fitment issue.

New mould pin already

implimented and logo

available at VECV is

rought at our end,parts

now send with checking

logo mounting on theart at PDI.

19-Jul G


9/19


Sno. Item Code Item Name Nature of Defects

JAN'13

FEB'13

MAR'13

APR13

MAY'13

JUN'13

JUL'13

AUG'13

SEP'13

OCT'13

NOV'13

Dec;13

Root CauseAction

Plan

Target

Date

Status

(RYG

)

8 IA22385 DASHBOARD PAINT PROBLEM 10

21 out of 24

Dashboards were

found with polythene

impression on it,.

Also there is

problem with the

paint application

which impart thick

layers on the part

which gives

polythene impression

even after proper

curing time.

Holes in the

polythene is done

after proper curing

time, also electric

heaters provide

better curing of part

as compared with

the earlier used gas

furnace oven.

17/07/201

3G

9 IA222215PANEL SHIELD

T/M LOWERDAMAGE 1

Handling damage at

VECV.... NIL G

10 IC322032 Cover Plate Assy. Metal insert removing 5

the adhesive which

we are using is notcompatible to adhere

the metal insert with

ABS .

We are planning to

change our processof joining of metal

insert with ABS8/12/13

G

11 IA302841

ENGINE HOOD

ASSY

Hinge Inclined 1

CD Dimasion of the

hole was found

shifted due to which ,

The hinge found

tilted with respect to

cd dimension

Checking gauge

provided at PDI to

check the hole CD.

Immediat

e G

TOTAL 1 14 2 1 8 0 13 4 1 1 5 1


10/19SIA Monthly Review PPT

WATCH KPI TRENDS.No. WATCHED KPI

MEASUREJAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

-MENT

1In-house monthly PDI

PPM

TOTAL Qty 64687 52930 66373 76000 80401 75486 74546 59406 37720 54275 27955 61144

REJECTED 242 200 250 253 323 195 390 286 205 208 98 169

ACTUAL 3741 3778 3767 3470 4020 2580 5231 4814 5434 3680 3520 2760

TARGET 3800 3800 3800 2500 2500 2500 2000 2000 2000 1500 1500 1500

2-AIn-house monthly

Process PPM (Molding)

ACTUAL

Activity started from may

-* 2680 3338 8678 2800 2000

TARGET 3500 3500 3200 3200 5000 3000 3000 3000

2-BIn-house monthly

Process PPM (Filing)

ACTUAL

Activity started from september8931 4950 4800 4850

TARGET TBF 5000 5000 5000 5000

2-C

In-house monthly

Process PPM(Painting)

ACTUAL

Activity started from september

11139 8051 9580 6850

TARGET TBF 7000 7000 7000 7000

3In-coming monthly

PPM

ACTUAL 3400 0 0 0 0 0 0 0 0 0 0 0

TARGET 4000 4000 4000 3500 3500 3500 3000 3000 3000 2500 2500 2500

4

No of DOL partsACTUAL

61 61 58 60 62

(Total 68 parts)TARGET

62 62 62 63 63 63 65 65 65 66 66 66

5

PDI Execution (% ofPDI followed

invoices/Total invoices

raised)

No OF PDI 60 55 50 55 51 50 51 60 60 55 55 55

ACTUAL 100 100 100 100 100 100 100 100 100 100 100 100

TARGET 100 100 100 100 100 100 100 100 100 100 100 100

6Process audit (No of

parts )

ACTUALActivity started from may

5 5 3

TARGET 5 5 3

7

Dock audit (No of

parts)

ACTUAL

Activity will start from june

30 10 10 10 10 10 10

TARGET 30 10 10 10 10 10 10



S.No. WATCHED KPIMEASURE

-MENTJAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

8

Raw material

inspection plan

ACTUAL

Activity started from

APRIL..

2 2 2

(Third party)TARGET

2 2 2

9Layout inspection

(No. of parts)

ACTUAL 7 7 5 5 10 8 6 9 6 9 8 4

TARGET

7 7 5 5 10 8 6 9 6 9 8 4

10IMTE and Gauge

Calibration

ACTUAL .. 11

TARGET

.. .. .. .. .. .. .. 8

11

Tooling validation

(Dies, Jigs & Fixture

validation &

Maintenance)

ACTUAL

Activity started from may..

3 2 5 3 3 3 3 3

TARGET 3 2 5 3 3 3 3 3

12 Poka YokeACTUAL 1 1 1 1 0 2 0 1 0 2 2 1

TARGET 1 1 1 1 2 2 2 2 2 2 2 2

13 QS Sign offACTUAL

Activity will start from june..0

TARGET 40 26

14 System audit scoreACTUAL 85%

TARGET95%

KPI Summary

Months Jan-13 Feb-13 March-13 Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13

KPI R Y G R Y G R Y G R Y G R Y G R Y G R Y G R Y G R Y G R Y G R Y G R Y G

Watched 0 0 1 1 0 0 0 0 1 0 0 1 1 0 0 0 0 1 1 0 0 0 0 1 6 0 7



Open Red KPI Status

S.

No.KPI Month

Red

ParameterReason Root Cause Action

Target

DateResp. Status

1

controlled

g

2

W

atched

Inhouse

RejectionHole Not Clear

During painting

metafill deposition

mistakenly on the

part lead to hole

block.

Painting supervisor

instructed to check part

visually before sending

to PDI. & Clear hole

before proceeding

ImmediateMayur

AjmeraG



Road-map status to achieve KPI

KPI Action to achieve the KPI TARGET RESPONSIBILITY

In-house monthly PDI PPM In process improvement & in process

checking June'13 Mr.Mayur Ajmera

In-coming monthly PPMSupplier up gradation through

supplier audit July'13 Mr.R.Patidar

No of DOL parts

100% gauging implementation, And

special focus on repeated issue July'13

Mr.Mayur

Ajmera,Mr.Laxman

Surage and

Mr.Mayaram Sharma

Defect analysis in QRQC Jan'13 Mr. Jasvin S Bhatia

Information of defect to the down

level through involvement of

workers in QRQC Jan'13

Top Management

Process auditStrengthening the QC department June'13 Top Management

Raw material inspection plan Third party involvement for

inspection July'13 Mr.Mayur Ajmera

Tooling validation (Dies, Jigs &

Fixture validation & Maintenance)Validation of drilling fixtures with in

4 months April'13 Mr. Rajan S Patta

Poka Yoke Daily QRQC & Involvement of CFT

team Jan13 Mr. Mayur Ajmera

System audit score

Internal Audit June'13 &July'13 QC & MR



Layout StatusS.

No.Month

Comp.

Planed

Comp.

Complet

ed

N. C.

obser

ved

N. C.

Closed

Cumulati

ve Open

N.C.

Reason for open NC

Target

date for

Open N

C

Resp. Remarks

1 Jan-13 7 7 0

2 Feb-13 7 7 1 1 0

3 Mar-13 5 5 0

4 Apr-13 5 5 1 1 0

5 May-13 10 10 2 1 1 Drawing req. from VECV.15 JULY

2013vecv

Horizontal slots

converted to vertical as

per req in air cleaner

cover assy.

6 Jun-13 8 8 1 0 1As per fitment part is ok, but still it is to

verify whether dim variation.

15 JULY

2013

Quality

dept.

7 Jul-13 6 6 0 0

8 Aug-13 9 9 1 1 0

9 Sep-13 6 6 1 1 0

10 Oct-13 9 9 1 0 0

Due to fouling of RH part in mudguard 12

mm trimming of the part has to be done

according to the fitment purpose, But the

LH (IA222296) IS SUPPLIED

ACCORDING TO THE WIDTH GIVEN IN

DRAWING .

15/10/1

3

VECV Mr.

Vinay

Gupta

The drawing has to be

revised according to the

reduced width

11 Nov-13 9 9 0

12 Dec-13 4 4 0

7 7

5 5

10

8

6

9

6

9 9

1

65

4

87

6

8

5

89

0

2

4

6

8

10

12

No. of Parts completed 100% Green Parts

0

1

0

1

2

1

0

1 1 1

00 0 0

1 1

0 0

1 1

0 00

1

00

1 1

0 0 0 0

0

0.5

1

1.5

2

2.5

Total N.C. N.C. Closed Cumm. Pending N.C.



In-house PPM Trend

PARETO FOR TOP CONTRIBUTOR

0

1000

2000

3000

4000

5000

6000

INHOUSE PPM TREND

PPM

34

26 2421

5

05

10152025

303540

REJECTED

QUANTITY

TOP CONTRIBUTOR OF DEC'13

In-house Rejection Status

S. No. Part No.

Non-

conformance

Detail

Repeated or

NotRoot Cause ACTION Target date Resp. Status

1 ID206599Hole Not

Clear

R

ep

a

t

e

d

During

painting

metafill

deposition

mistakenly

on the part

lead to hole

block.

Painting

supervisor

instructed to

check part

visually

before

sending to

PDI. & Clear

hole before

proceeding

ImmediateMayur

Ajmera

g

2 IA303087Hole Not

Clear

3 IA218893 Hole Not Clear



Improvement plan & status

IMPROVEMENT PLAN 2013

Sl. No Particulars PLAN DETAILS Target Responsibility

1

Quali

tyrelatedimpro

vements

Raw Material Inspection

Third party APRIL '13

Mr. Mayur Ajmera

2

Measurement of Raw

Material at shop floor MAY'13Mr. Abhinav

3

Avoid repeated customer

complaint JUNE'13Mr.Mayur Ajmera

4Dock audit to be conduct

JUNE'13Mr. Jasvin S Bhatia

5

Arrange of all gauges near

the working area. JULY'13

Mr.Jasvin S Bhatia

6

100% Guaging

Implementation of all the

parts JULY'14

Mr.Mayur Ajmera; Mr. Laxman Surage

7

Aim for 0 ppm at

customer end JULY'13Mr. Mayur Ajmera

8

100% will be checked in

layout report. JULY'13Mr.Jasvin S Bhatia

9To achieve quality System

Audit Score 95% AUG'13Mr. Mayur Ajmera

10

Punching Die

Implementation For all

types of mud flap AUG'13

Mr. Nikhil Jain

11

Machine for Dry

Sandering Is to Be Started

For Better Results SEP'13

Mr. Mayur Ajmera



POKA YOKE IMPLEMENTATION DEC13

CHECKING GAUGE FOR CD DIMENSION ENGINE HOOD ASSY IA302841

Checking of Hole By qualifying with PIN

CD dimension



General Awareness About 5S

Training conducted at our plant regarding general awareness

about 5 S, under the guidance of Mr. Sanjay Agrawal Sir.


19/19SIA M thl R i PPT

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