Quality Maintenance PillarAwareness Training

Programme

Quality Maintenance(Hinshitsu Hozen)

Background

Defects were high

No structured approach to analyze defects

No sustained effortsFor defect prevention

Process condition are not standardized

High process variation

No customer satisfaction

for survival

Background – QM Pillar

Survival

ZeroDefect

Competition

Quality

Customer Demand

Globalization

Customer Satisfaction

Why Quality

Aim – QM Pillar

To establish defect free manufacturing process where Quality is

built into the process leading to consistent product And Quality into the hands of Customer

Category Parameters UOMBM

(May'08)BAL Award

CriteriaTarget

(Mar'10)

Current Status

(Aug'09)Remarks

PProduction loss due to Defective Input Material

Hrs. -- -- -- 0 0Sustaine

d

Q

Customer complaints (PPM) PPM 19 -- 0 0 2Not

Achieved

In-house Rejection (PPM) - Plant Level

PPM 411980%

Down824 0 532 Achieved

In-house Rejection Phenomena - Plant Level

Nos. 60 -- -- 0 16 Achieved

Early Failure (PPM) PPM 0 0 0 0 0Sustaine

d

Warranty (PPM) PPM 1574 -- <100 <100 2779Not

Achieved

Supplier parts (PPM) PPM 23114 -- -- 0 2819Not

Achieved

C Scrap Cost (Rs/Comp) Rs. 1.2080%

Down0.24 0 0.21 Achieved

M QM Kaizens/employee/month Nos. 0.2 -- -- 1 1.2 Achieved

Target – QM Pillar

7

Identify defective component

Defect phenomena identification

Review Insp. Std. for adequacy of

Prepare QA matrix gauges, checking method, frequency

Stratify defect phenomena A,B,C wise Prepare revised std. PFMEA ,Process flowControl Plan

Analyze by why-why

Plan & implement counter measure

Trend graph

1.Make kaizen / countermeasurePrepare QM Matrix 2. Simplification of Inspection Method

Check conditions as per QM matrix and take actions before defect occurs identify Q component which have already caused defect and monitor it to sustain zero defect

Review results for effectiveness

•Achieving – •“Zero Defect”

Sustaining – “Zero Defect”

Approach

QM Master Plan

Master plan for Quality Maintenance is planning of various activities in this pillar with respect to the time frame in months and years. According to the stage of TPM implementation it can start at various levels. In the beginning it will start with data collection on defects to improving conditions to sustaining zero defect conditions.

10

QM Pillar – Master Plan

11

Defect Prevention

1.Customer complaint2.EFR /Warranty defects3.Inhouse defects (In process + Vendor parts)

12

Customer Complaint: Why do you have customer complaint?Because, you do not inspect the defect of your product. So, your customer inspects your product instead of you.On the other hand, even if you dispatch good quality, during transportation time, product gets damaged either due to poor packaging or products hitting each other.

When I ask, why customer complaint happens, usually your answer is “due to product defect”. The answer is correct. But I say this is not correct. May be you have big doubt. So I ask next question, why do you have in process and final inspection? You say, because if we do not do inspection, customer complaint will happen.

So finally customer complaint links to inspection.

13

Customer Complaint: Many companies have sampling inspection. Sampling means inspect some products, not all products. So, customer complaint comes from sampling inspection (not inspecting all). Even if 100% inspection, visual inspection is dangerous. Because Poka (Missing, mistake by human being) problem. Poka is very natural. If you say, I never mistake, it is already a mistake.

When I ask the company, why you do not do 100% inspection perfect final inspection? They say, we need a lot of time, manpower, some investment money. I ask the next question, which is important between customer complaint zero and additional money? They have some excuse. This answer depends on top management, not operator.

I ask operator, how many defects did you observe today? Operator replies “Zero”. I say, you did not inspect all products. So, of course, defect is zero, but at next process customer complaint is not zero. Defect and customer complaint is like a balance. (A) (B) 0-----------------------------0 (A) – Defect (B) – Customer complaint

14

Customer Complaint: Next case: if in process is zero, do we need final inspection? I say, you do not need. But I ask, is it possible that in process defect is zero? If you say “Yes”. Please explain “ how to do”. If you can not explain, I say inspection is necessary.

Conclusion:To challenge “Zero” Customer Complaint, you must change inspection method.

* Sampling inspection to 100% inspection* 100% visual inspection to 100% gauge inspection* 100% gauge inspection to 100% Instrument / machine inspection with Poka Yoke.

* How to prevent Poka is very important.

15

Warranty: Warranty happens due to weak strength, forced deterioration, especially Poka, wrong parts and slight defect, which is very dangerous. TOYOTA says, Quality is the guarantee for product life (part’s life). That is, you can confidently say, after market, up to 40,000 KM no problem. Quality means exactly “No problem”

In-process defect: When I ask why do you need in process inspection? What is your answer? If you say, prevent customer complaint, this is not correct. The correct answer is , we have to know whether all 4MT conditions are OK or not. 4MT conditions; machine, material, process method, man (Poka yoke),tool and then especially Deterioration is within limit or not.Processed product is the result after processing. We need to ensure the cause side of condition before processing. Generally your in process inspection is against processed product. That is after defect, you need some adjustment.In this case maintaining in process defect “Zero” is very difficult. Hence inspection is necessary during in process.

16

How to achieve / prevent Zero customer complaint?

Customer Complaint Prevention Customer Complaints (BAL)

Suppliers (Varroc)

Understanding the complaints

Stratifying the complaint

Accepted Not Accepted Customer Arriving at Consensus

Cause side Defect Matrix

Technical

Analysis

Finding Root cause/s

Kaizen/ Poka Yoke / Action

Non-Technical

Revisit Facilities

Strengthen/Input Facilities

Education to operators

OJT

Audit by supervisors

Course Correction/Demonstration

Sustenance

Inspection side

Strengthening Inspectionmethod

Implement

Analysis

Sustenance Action

See Result

OK

Not OK

Sustenance Action

See ResultOK

Not OK

18

How to sustain Zero customer complaint?

Sustenance Action Zero Customer Complaint

Zero CC

How ?

Ensure Improvement

of working

PM of inspectionequipment. PokaYoke to prevent

failures

PreventSkip case

Prevent mix up of not ok

with ok

Sustain Zero CC

Inspection Improvement

Customer Complaint (CC)

Interlock

Kaizen, Poka yoke,Design Improvements etc

JH check sheet for checking whether working or not.PM check sheet for repair if not working

1) Verify present status2) Survey of process which generated defect3) Survey and analysis of 4M conditions4) Study of malfunction countermeasures5) Analysis of conditions for non-defective units that

are not confirmed6) Improve 4M condition defects7) Setting 4M conditions8) Intensification and improvement of check methods9) Deciding check reference value10) Standard revision and trend control

10 Steps of Quality Maintenance

Data Collection on defectsIdentify total no. of defect phenomenaShop /Cell wise stratificationPreparation of Defect matrixSelecting component for further study based on priorityStudy the component drawing for inspection & inspection standard availability

Step-1 – Verify present status

Defect Classification

OK

OK

NOT-OK

‘A’ TYPE DEFECT

Action taken by Operator

Limit of output

specification

•The output is (OK ) initially

•Becomes Not ok

•Corrective action action by operator

•Becomes OK

Root causes analysis Tool

Why Why Analysis

Defect Classification

LSL USL

A type Defect - Examples

PU Foam Short MouldingMirror Finger Mark

Flywheel Magneto Pulsar pip radius undersizeStarter Motor Core cut during unbalance correction

Gear Face damageCrank pin Chamfer not ok

Division Product Category A Type Defect

Polymer

Electrical

Metallic

NOT-OK

‘B’ TYPE DEFECT

No Action by operator

Limit of output

specification•The output is (OK ) initially

•Becomes Not ok

•NO action taken by operator

•Becomes OK

Root causes analysis Tool

PM Analysis or

C & E Diagram

OK

OK

Defect Classification

LSL USL

Division Product Category B Type Defect

PolymerPU Foam Foam uneven feel

Extrusion Black spot

ElectricalFlywheel Magneto Rotor case damage

Flywheel Magneto Dent mark on taper

Metallic Gear Bore ovality

Crank pin Pitting mark

B type Defect - Examples

OK

‘C’ TYPE DEFECT

Action by taken operator

Limit of output

specification •The output is (Not OK ) initially

•Action taken by operator

•Becomes OK (Setting scrap)

Root causes analysis Tool

Why ,Why Analysis or

C & E Diagram

Not OK

OKLSL USL

Defect Classification

Plastics Flow markExtrusion Zig Zag cutting

Flywheel Magneto Marking not visibleStarter motor Commutator tag melts during hot stacking

Gear Span oversizeCrank pin Outer diameter damage

Division Product Category C Type Defect

Polymer

Electrical

Metallic

C type Defect - Examples

Sr. No.

DEFECT PHENOMENON (IN-PROCESS)

DEFECT TYPE

Sept'07 Oct'07 Nov'07 Dec'07 Jan'08 Feb'08 Mar'08 Apr'08 May'08 Jun-08 Jul-08 Aug-08

1 Drill hole through during balancing C 27 6 5 0 0 0 0 0 0 0 0 0

2 Rivet head damage A 5 4 0 1 0 2 0 0 0 0 0 0

3 Bolt broken B 25 24 13 0 4 3 0 0 0 0 0 0

4 Double marking A 11 12 0 0 0 0 0 0 0 0 0 0

5 Pip radius oversize (>57.75mm) B 121 140 7 0 3 0 0 0 0 0 0 0

6 Boss thread damage A 0 25 21 12 17 8 26 15 8 21 12 10

7 Magnet case scratch mark A 31 32 1 2 0 0 0 0 0 0 0 0

8 Plate starter clutch damage A 77 67 12 7 2 11 7 0 0 0 0 0

9 Magnet case up B 57 124 11 2 1 8 4 0 0 0 0 0

10 Pip radius undersize (<57.95mm) B 60 80 29 0 0 0 0 0 0 0 0 0

11 Magnet case shift A 31 35 7 3 0 0 1 0 0 0 0 0

12 Taper dent mark B 12 9 7 6 9 12 7 8 3 0 0 0

13 Keyway damage A 25 48 12 8 7 5 12 10 12 6 12 0

14 Pip damage A 11 15 12 9 11 15 12 10 9 12 9 9

15 Magnet case damage B 101 86 57 33 31 62 65 74 67 49 52 33

Sr. No.

DEFECT PHENOMENON (VENDOR PARTS)

DEFECT TYPE

Sept'07 Oct'07 Nov'07 Dec'07 Jan'08 Feb'08 Mar'08 Apr'08 May'08 June'08 Jul-08 Aug-08

1 Cup notch shift A 21 6 32 5 0 0 0 0 0 0 0 0

2 Rotor ID gauge tight due to cup F/O more B 96 76 31 14 37 27 15 0 0 0 0 0

3 Rotor ID gauge tight due to cup Magnet profile B -- -- -- -- -- -- 17 0 0 0 0 0

4 Boss Ø 85 oversize A 8 27 14 9 3 3 2 2 5 0 5 0

5 Boss thread miss A 2 16 11 1 4 5 2 2 2 0 2 0

6 Boss thread oversize A 43 56 79 0 45 52 29 47 35 22 24 32

7 Cup poor plating -- 49 20 17 36 67 93 32 30 52 48 52 0

8 Boss thread undersize A 84 46 39 0 1 1 0 0 0 52 0 0

9 Others -- 18 27 46 32 8 12 6 0 0 0 0 0

PHENOMENA WISE MONTHLY REJECTION QUANTITY MATRIX ROTOR ASSEMBLY

Study of possible and happened defect phenomena in past for similar component.

QA Matrix for quality characteristics based on process survey (Possibility)QA Matrix updation based on defects occurred

Step-2 – Survey of process which generated defect

Prepare Quality Assurance matrix & reflection in standards

QA Matrix – QA (Quality Assurance) Matrix is used to find out sources of defects in product. QA matrix shows the relation ship between defect/defect mode & the process which causes it. It requires data collection for defects at various process stages to prepare a QA Matrix. Hence QA matrix is to be made quality defect wise, process wise and machine wise.

SupplierInward

InspectionRiveting Soldering

Switch Mfg. Line

Testing on Switch

Line

Handle Bar Mfg.

Line

Final Testing

Transportation

Throttle not self return

Adjuster nut loose

Switch loose with twist force

Front brake cable bellow spring end bend

Switch not working ( Horn some time continue)

P

Horn switch continous on

P

P

Clutch lever stickyBlinker switch not operate

P

Head light switch not working

P

Front Brake cable thread damage

Handle bar assembly - Platina ( 52DU0033 )

DEFECT OCCURANCE STAGE IN PROCESS INSPECTION

PROCESS CHANGE POKA-YOKE P

BOLD - ACTION TO BE TAKEN

NOT BOLD - ACTION COMPLETED

QA Matrix

Step-3 – Survey and analysis of 4M conditions

This analysis is a set of conditions with respect to Man, machine, material and method for obtaining a good products. It helps in identifying 4M standards and checking is possible against these standards. Removing this variability can some times eliminate Quality defects in the product.

Caused by Raw Material conditions

Caused by Equipment precision

Caused by Method Conditions

Caused by Condition of people involved

Producing materials not generate defect

Search for materials not generate defects

Fostering vendors not cause defects

Set condition of material not to generate defect

Manufacturing equipment not generate defects

PMAnalysis

Improvements to Equipment not generate

defects

Set Conditions of equipment not generate

defects

Devising methods not generate defects

Search for Methodsnot generate defects

Improvements to Methods not generate

defects

Set Condition of method not generate defects

Fostering operators strong in equipment and job

Autonomous maintenance & skill Education training

Management of conditions not generate defects

Zero Quality Defect

Trouble finding

Process and recovery

Maintenance & mgt

Quality Defect factors -4MT

Pursue relationship Between Quality Char &

Material / EquipmentMethod conditions

Manufacturing Equipment not generate defects

4MT Condition to decide Quality4M 4M Conditios: Machine What will happen if conditions are not observed.

Equipment Conditions:

1) Cleaning is thorough1) If not cleaned, dust will drop during processing to cause attaching or mixing of foreign matter to cause defects.

2) Lubrication is precise2) If not oiled properly, machines do not operate smoothly and cause process defects.

3) Bolts and nuts are tight3) If loose,machine parts will have rattle and cause process defects.

4) Equipment parts are tight 4) If there is rattle, process defects will result.Jigs Conditions:1) Scratches and press marks cannot be found on jig mounting parts

1) Any press marks will cause process defects.

2) Scratches and press marks cannot be found on mounting reference planes of processed articles

2) Any press marks will cause scratches on products or process defects.

3) Wear and chipping cannot be found on jig parts 3) Any wear will cause process defects.

Tools Conditions:

1) Right tools are used1) If the right tools are not used, bolt can not be tightened fully and processing defects will results.

2) Tools are set correctly 2) Improper centering will cause process defects.3) Tools do not have chipping or wear 3) Any chipping or wear will cause process defects.Measuring device conditions:1) Probes of meters are free of dust 1) Dust on probes will cause measuring errors.2) Measuring devices operate smoothly 2) If not smooth, measurement errors will result.

3) Measuring devices are within calibration period 3) If precision is not accurate, measurement errors will result.

Equipment, Jigs, Tools, Measuring

devices

4MT Condition to decide Quality

4M

A) Is quality of materials that affect process quality good?

A) Is before process quality that effects process quality good?

1) Materials are free of scratches and dust 1) Before - processed goods are free of scratches and dust

2) Material composition and texure are stable. 2) Before - Process dimensions are not dispersed … & others

3) Material hardness is stable ….. & others

4M Conditios: Material

Materials

4MT Condition to decide Quality

4MA) Are processing conditions to produce good quality good?

B) Are the right work methods used?

1) Are rpm and feed speed settings good?1) Are processes goods mounted correctly on reference planes? Are not they mounted with dust attached?

2) Are decided conditions followed? 2) Are measurements made with right measuring procedure?

3) Are temperature and density settings good? Are they followed?

3) Are measuring specifications prepared for measuring devices? Are they followed?

4) Are pressure and flow rate settings good? Are they follwed? … and othersC) Are measuring methods right?1) Are measurements made without errors?2) Are measurements made with right measuring procedure?3) Are measuring specifications prepared for measuring devices? Are they followed?

4M Conditios: Method

Processing conditions,

Work methods and Measuring

methods

4MT Condition to decide Quality

4M 4M Conditios: Men

Men (Morale) Strong will that always following standards will produce good quality

Morale mentioned here is the " will to do". It is the will to improve quality and is a strong problem-consciousness to be concerned very much with slight defects that impair quality and to solve them by all means.

Strong problem-consciousness to thoroughly extract 3M malfunctions points (slight defects) if defects are found.Overconcerned with a phenomenon which is strange or is slightly different from the usual in daily

Corrective action (Kaizen / Pokayoke) for the defect phenomena.Refer QA Matrix prepared earlier.Consider all 4M conditions for the defect.Analyze the defect & implement countermeasures for the root cause and possible causes.

Step-4 – Study of malfunction countermeasures & restore malfunctions.

41

The word “KAIZEN” is basically Japanese word. “KAI” means Continuous & “ZEN” means Improvement.So Kaizen is nothing but Continuous improvement.

The starting point of any improvement is to recognize the need of change. It comes from recognizing a problem which comes from individual eye-capability to see what is not right.What is MUDA (Waste), MURI ( Inconsistency) & MURA (Strain) loss.

Kaizen topic includes : 1) Rejection (defect) 2) Manpower 3) Technique 4) Method 5) Time 6) Facilities 7) Jigs / Tools 8) Materials 9) Production volume 10) Inventory 11) Place (space) 12) Safety etc.

Kaizen for eliminating defects

There are mainly 3 types of Kaizen.

1. 2 Quadrant Kaizen

2. 4 Quadrant Kaizen

3. Concentrated Kaizen

42

TPM Circle No.: Activity KK JH QM PM SHE OT DM E&T

COMPANY LOGO / NAME TPM Circle Name: Loss no./StepResult Area P C D S M

Cell No.: Cell Name: Operation :

Kaizen Theme: Idea:

Bench Mark Problem / Present status: Target

KAIZEN StartKAIZEN FinishTeam Members:

Benefits:

Why Why Analysis : Results: What to do :

TargetDate

Registration no. & Date : Registered by :Manager's Sign :

Responsibility StatusSr no

E.g. Increase production, Reduce time / cost etc

(Indicating "Howt to check / audit to ensure that

Scope & Plan for Horizontal Deployment

Model

(Implementating this kaizen at all possible cases in existing product.(Check & confirm repurcations of changes being suggested before implementating)

(Always starting with "Providing / Changing)

Dept: Kaizen No.:

COUNTERMEASURE :

(E.g. Poka Yoke, More friction, Fully, More bolts, More coolant, Big, Short, Can detect, Easy)

Machine :

(Correct observation. Use of 5W 1H)(When = Trend / Time / Period: Contienous / Discontineous / Rare, Start up / Seasons / Set up),(Who =Men:Day shift / Night shift / New employee / Temporary help), (What =Materials: Lots / Type), (Where = Locations: Part / Range / Process / Equipment), (Which = Trend: Direction e.g. possitive, Negative, Rear, Left, Right etc / Increase / Reduction), (How -How much/How many) = Status: Equipment / Jig / Tools / Accuracy / Machining conditions etc)

Q - Def. A / B / C

Process / Stage :

How to do :

KAIZEN SUSTAINANCE :

(Always opposite to root cause)

(E.g. Reduce time, Reduce frequency, Eliminate, Increase life etc.)

(E.g. Poka, Less friction, Partly, Less bolts, No coolant, Small, Long, Can not detect, Difficult)

Always start with To prevent /To Reduce / To Increase ( Prevent for failure / rejection / accident etc. To Reduce for time parameters like set up & cost, To increase for productivity)

the kaizen will be effective in long run"

the kaizen will be effective in long run"

Root Cause :

(Indicating "What to check / audit to ensure that

Please insert graph indicating appearance of the defect on which action is taken. Monitoring for few months is necessary to check effectiveness.(Rejection for the specific problem)

Why Why analysis in brief: Analysis showing as how the REAL root cause was identified.

(Implementating this kaizen at all the possible case in the existing / similar products to arrest possibilities of this defect in similar current products.

Pokayoke for eliminating defects

Poka yoke is a technique for avoiding simple human errors at work.

Poka is a Japanese word meaning “Inadvertent error” and Yoke comes from Japanese word Yokerie meaning “to avoid”.

This has been termed as “Mistake / Fool Proofing”.

ERROR ARE INEVITABLE BUT CAN BE ELIMINATED

People always make mistakes. These can be reduced or even eliminated. Some of the Poka-Yoke devices, which can help to avoid defects are:

Guide Pins / Locators of different sizesError Detection Buzzers & AlarmsLimit Switches, Proximity & Photo sensorsCountersChecklists

Pokayoke for eliminating defects

Basic classification of Poka yoke

• PREDICTION V/s DETECTION

• ALARM V/s SHOTDOWN Vs CONTROL

• CONTACT V/s FIXED VALUE V/s MOTION READING METHODS

Example : Prediction or Prevention :

Pins

• Figure A shows that holes are wrongly drilled due to incorrect positioning of plate.

• Figure B shows that incorrect positioning of plate is prevented by locating 4 reference pins.

A B

Pokayoke

Example : Detection

• Figure A shows that plate with 4 holes drilled is to be dispatched to the customer. Customer complaints show many plates with 3 holes drilled.

• Figure B shows that mistake of less drilled holes is detected through a check by using 4 locator pins on a gauge.

A B Pins

Pokayoke

Type of sensing Devices :

1. Limit switches, Micro switches

2. Proximity switches

3. Photoelectric switches

4. Beam sensors

5. Sensor to detect changes in physical condition like temperature, pressure etc. (Pressure switches, thermostats etc.)

Pokayoke for eliminating defects

POKA-YOKE SHEET Varroc Engineering Pvt Ltd.

Problem :

Key Improvement :

Solution :

AFTERBEFORE

Prevent Error

Alarm

Control

Prevent Error

Detect Error

Sustenance Plan :

6W2H Format

Action plan - 6W2HSustenance

Qty. of defect actionsJul-07 Aug-07 Sep-07 BEFORE AFTER BEFORE AFTER

Def

ect

Com

pone

nt

Pro

cess

/ O

pera

tion

Roo

t cau

se

Qua

ntity

of r

ejec

tion

in 3

con

secu

tive

mon

ths

Insp

ectio

n st

atus

bef

ore

impr

ovem

ent w

ith

poss

ibili

ty o

f def

ect n

ot n

otic

ing

due

to

1. In

spec

tion

skip

2. N

o In

spec

tion

3. In

spec

ted,

but

def

ect n

ot id

entif

ied

( W

eakn

ess

in In

spec

tion

)

Insp

ectio

n st

atus

afte

r im

prov

emen

t with

act

ions

on

1.

Insp

ectio

n sk

ip2.

No

Insp

ectio

n3.

Insp

ecte

d, b

ut d

efec

t not

iden

tifie

d

Sta

tus

at th

e st

age

whe

re d

efec

t is

man

ufac

ture

d

Cou

nter

mea

sure

at t

he s

tage

to e

limin

ate

defe

ct

1. P

rovi

de2.

Mod

ify

Per

son

resp

onsi

ble

for

Insp

ectio

n im

prov

emen

t, C

ount

erm

easu

re a

t sta

ge a

nd s

uste

nanc

e

Dat

e of

com

plet

ion

of a

ctio

ns.

A -

Act

ion

not y

et p

lann

edB

- A

ctio

n un

der

prog

ress

C-

Act

ion

com

plet

ed a

nd e

ffect

iven

ess

conf

irmed

.

JH o

r P

M a

ctiv

ities

to e

nsur

e th

at d

eter

iora

tion

in

wha

t we

have

1. P

rovi

ded

2. M

odifi

ed

is n

otic

ed b

efor

e de

fect

occ

urs

and

rest

ored

.

HOW MUCH WHO WHEN STATUSINSPECTION SIDE CAUSE SIDE

HOW TO DONo

WHAT WHICH WHYWHERE

Study of other possible reasons for a defect, PM Analysis in some cases.

Find out conditions / control items from actual defects & possibility study for contributing non defective units.

Step-5 – Analyze conditions for non defective units that are not confirmed.

Execution of PM Analysis for exposure and handling of malfunctions

What is PM Analysis Deviation from Normal to

abnormal Physical principles behind an

abnormal event.

Understand the mechanics of abnormal event and

understand the mechanism of equipment.

Understand the relations between the abnormal event and 4M.

Phenomena

Physical

P

Mechanism

Machine

M

ManMaterialMethod

PM Analysis is one of the most effective techniques to handle B types of defects. PM denotes (P) Physical phenomena (M) Mechanism. In this analysis we try to establish the relationship between phenomena and the physical mechanism behind it which explain the contributing conditions to cause such physical mechanisms.

These contributing conditions are then elaborated in terms of relationship with primary (man, material, machine, method) conditions. Usually these primary conditions are not measurable so they are once again converted into secondary conditions that can usually be physically inspected against a standard.

Execution of PM Analysis for exposure and handling of malfunctions

Survey, analysis & implementation of 4M conditions for possible and happened defects.

Carry out possibility study, identify all 4M conditions to ensure that defect does not occur.

Step-6 – Improve 4M Condition defect Step-7 – Setting 4M conditions

ManMachi

neMateri

alMetho

dTool / Fixt.

Control Item Check PointSpecification /

CriterianJH PM- MC/TM

PartName

Check Point

SpecificationInspectio

n Location

Inspection at Stage

P Cutter Face Runout < 0.010 mm Max Face Run out Monitoring on graph - Monthly

---

P Cutter Adoptor OD Ø 31.73 / 31.74 mm OD Monitoring on graph - Monthly ---

P Cutter Adoptor OD Runout < 0.010 mm Max OD Monitoring on graph - Monthly ---

P Locator OD Ø 68.63 -0.005/ -0.015 mm

OD Monitoring on graph - Weekly Replace the Locator - Frequency - 6 months

P Locator OD Runout < 0.010 mm Max Run out Monitoring on graph - Weekly

Replace the Locator - Frequency - 6 months

P Locator Face Runout < 0.010 mm Max Run out Monitoring on graph - Weekly

Replace the Locator - Frequency - 6 months

P C Washer Condition No wear & Crack Check Daily Grind the washer face - Frequency - 3 months

P Fixture Fixture Face Free from chips Clean the fixture face by Air J et - after Every J ob

Grind the fixture face - Frequency - 3 months

P Cutter Cutter Wear Change cutter after 300 nos.

Monitoring by Tool Life Record and Tool counter

---

P

Cutter Cutter Life Total no of Resharpening - 15 (Life - 45,000) (No Overuse)

Monitoring of Tool Resharpening by Tool store

---

P Cutter Setting Cutter Setting as per Procedure displayed

--- ---

P Component Face

No Burr on Resting area

--- Visual

P ID 68.63/ +0.03 By Plug Gauge

P Width 15.5 15.5±0.10 By Dial & Comparator

P Width Variation

15.5±0.10 By Dial & Comparator

P

Notch Milling Presence of Notch Milling

Supplier End by Special Gauge

---

P

Cutting oil Coolant flow-Pressure & Direction

Coolant flow guided on cutting point

1)Check coolant oil level as per Minimum & Max. mark-Daily2)Check coolant knob position as per mark-Daily

Replace cutting oil as per PM plan-One year

P Punch Locator OD Ø 68.63 -0.015/ -0.025 mm

- Replace - Yearly

P Marking Punch Point Wear No wear & Crack Visual - Daily Ground - monthly

Sr No

Output

1Span 32.22 -0.05/-0.15

over 4 Teeths

4M-T In Process

Part Name & No : Starter Gear 3 W 4S ( 52 AA 0208) Operation : Gear Shaping3 M & 4 T Conditions

Input Material

4 M & T Condition

MAN

MATR

L

M/C

METH

OD

TO

OL A B C

* *Air

pressureHigh pressure

Pressure regulator error

2.5~3.8 BarPressure gauge

SOS Operator JH sheet* Check point added in TBM for regulator output.* Pressure gauge callibration as per plan.* Pressure switch to be provided on machine.

* *Valve

opening time

Opening time more

Timer malfunctioning

To be specified by PED & verified by

Maint.

* To arrive method for valve opening time & check point to be added in m/c TBM.

* *Valve

opening distance

Distance more

Pressure regulator error

To be specified by PED & verified by

Maint.

* Check point added in TBM for regulator output.* Pressure gauge callibration as per plan.* Pressure switch to be provided on machine.

* *Air

pressureLow pressure

Line pressure variation

2.5~3.8 BarPressure gauge

SOS Operator JH sheet* Pressure switch to be provided on machine.* Pressure switch callibration as per plan.

* *Valve

opening time

Opening time less

Timer malfunctioning

To be specified by PED & verified by

Maint.

* To arrive method for valve opening time & check point to be added in m/c TBM.

* *Valve

opening distance

Distance lessPressure

regulator error

To be specified by PED & verified by

Maint.

* Check point added in TBM for regulator output.* Pressure gauge callibration as per plan.* Pressure switch to be provided on machine.

* *Home

position sensor

Home position sensor

disturbed

Home position sensor mounting

loose

Sensor to match the marking line

Visual SOS Operator SOP

* Check point to be added in TBM check sheet.* Check point to be added in JH check sheet to confirm home position.

* *Adhesive

lay patternPattern shrink Timer belt slip

Pattern as per master pattern

Visual SOS Operator SOP* Check point to be added in JH check sheet for pattern lay.* Add timer belt in TBM part's calander.

2Passivaion removal

Passivatiov partially removed

* *Buffing time

Time lessTimer

malfunctioning8 Seconds Timer 100% Operator SOP

* Buzzer provided to prevent early removal of yoke & interlocked with next cycle

* *Input

voltageVoltage low

Variation in input voltage 225±25 Volt Voltmeter 100% Operator SOP

* Stabaliser to be provided with magnetizer to maintain reqd input voltage.* Calibration of voltmeter

* *Coil

ResistanceResistance

lowCoil short 8 .0 +/- 1.0 ohm Multimeter

1/3 months

Maintenance

TBM check sheet

* magnetizer coil PM as per TBM plan.

Less removal of passivation

* *Passivation removal

Less removal of passivation

Early removal of yoke from buffing m/c

Passivation removal time 8 sec.

Timer 100% Operator SOP*Buzzer provided to prevent early removal of yoke & interlocked with next cycle

Less removal of passivation

* *Buffing pad change frequency

Non removal of passivation

Excess usage of buffing pad

replace after every 30 cycles

counter1/30 cycles

Operator SOP* Counter interlocked with m/c.* Check point added in JH check sheet.

Foreign particles in yoke I.D

* *Yoke ID cleanliness

Foreign particles in yoke ID

Buffing dust inside yoke ID

Yoke ID should be clean

Visual 100% Operator SOP* Yoke ID cleaning with cotton cloth check point added in SOP.

1

3

4

Pre-magnetization

clamping force not enough

Passivation removal

Anabond qty more

Anabond qty less

Anabond pattern shift

Anabond application

RECORD/ DOCUMENT

ACTION TAKENCRITERIA

(Specification) CHECKING METHOD

FREQ. RESP.

DEFECT TYPE

CONTROL ITEM

ABNORMALITYCAUSE OF

ABNORMALITYSr No

MACHINE / STAGE NAME

DEFECT PHENOMENA

4MT CONDITIONS

4M1T Condition Study For Magnet Bonding Process

Review 4M conditions set before and after actions implementation.

Step-8 – Intensification & improvement of checking method

Review QM (Quality Maintenance )Matrix for control items identified to produce non defective itemsPrepare inspection manual for control items, to simplify inspection activityIntroduce control items as check points in JH, PM check sheets for effective monitoring.

Step-9 – Deciding check standard valueStep-10 – Revise standards

Feedback

* DAILY INSPECTION

MP DESIGN

KK

JH

PM

DM

E & T

PM ANALYSIS

KAIZENS

7 STEPS OF JH

Application ofEquipment diagnosis Technology

Fostering proficiency of Employee in Equipment operation & maintenance

Quality Maintenance

EQUIPMENT: NOT PRODUCING QUALITYDEFECT

SETTING OF CONDITIONS (Decide Rightly)

CONDITION MANAGEMENT (Follow Strictly)

ACCOMPLISH ZERO DEFECTS

Relationship between the pillars of TPM activities and Quality maintenance

THANK YOU