Analysis of online defects in mass production of automobile

8/10/2019 Analysis of online defects in mass production of automobile

1/22

nalysis of online defects in mass production of

automobile

By:

VARUN MALIK

M.Tech - Auto

A2326213033

Under the guidance of:

Prof. VIVEK KUMAR

HoD, MAE

Amity University, UP


2/22

Vehicle Inspection department is responsible for the following :

1. Safety - Zero Accident

2. Quality

GCA(Global Customer Audit ) Score Improvement

PDI(Pre delivery inspection ) Defect percentageReduction

Defect Free vehicle to customer

3. Capability Development

4. Operational Cost Reduction and Productivity Improvement

5. New model quality Up gradation and sustenance

A GLIMPSE OF VI


3/22

VEHICLE INSPECTION 1 PROCESS SEQUENCE


4/22

DRUM

TESTER

DYNAMIC CHECKING OF VEHICLES FOR

CHECKING VEHICLE PERFORMANCE

BRAKE

TESTER

FUNCTIONING OF FRONT / REAR BRAKES

AND PARKING BRAKES

6 ENGINE ROOM

1. EMISSION CHECKING AS PER

REGULATIONS

2. WIRING AND PIPING CHECKING INSIDE

ENGINE ROOM

7PIT

INSPECTION

UNDERBODY INSPECTION FOR COOLANT ,

TRANSMISSION OIL, ENGINE OIL LEAKAGE

5


5/22

8 SHOWERTESTER

WATER LEAKAGE CHECKING INSIDEPASSENGER CABIN

9 ROAD TESTDRIVING PERFORMANCE CHECK ON ROAD

TESTING

10FINAL

INSPECTIONRECHECK OF REPAIRED DEFECTS.


6/22

SHOP LAYOUT

FIRST PPER NCE CHECK

T

O

E

D

J

U

S

T

M

E

N

T

S

I

D

E

S

L

I

P

D

R

U

M

T

E

S

T

B

R

K

E

T

E

S

T

E

N

G

I

N

E

R

O

O

M

SHOWER TEST

SHOWER TEST

H LF RO D TEST

RO D TEST

FIRST PPER NCE CHECK


7/22

PROJECT TITLE

Analysis of online defects in massproduction of automobile


8/22

REQUIREMENT OF THE PROJECT

CUSTOMER

SATISFACTION :

LOSS IN QUALITY

EXTRA MOVEMENT OF NGVEHICLES

EXTRA

REPAIR

EXTRA TIME CONSUMPTION

LOSS IN

EFFICIENCY


9/22

ADOPTED METHODOLOGY

GENCHIGO TO THE ACTUAL PLACE

GENBUTSUOBSERVE THE ACTUAL THING

(GENJITSUACT TO RECTIFY THE PROBLEM)

EXECUTION OF SUZUKIs 2G/3G


10/22

A. TESTER LINE DEFECTS - RESULTS

Defects

0

10

20

30

40

Defects

Trend of Total Defects per day

Omni

Eeco

Wagon R

Ritz

Alto-800

Model wise bifurcation


11/22

A. TESTER LINE DEFECTS - RESULTS

20 May

Omni

Eeco

Wagon R

Ritz

Alto-800

21 May

Omni

Eeco

Wagon R

Ritz

Alto-800

22 May

Omni

Eeco

Wagon R

Ritz

Alto-800

23 MayOmni

Eeco

Wagon R

Ritz

Alto-800

24 May

Omni

Eeco

Wagon R

Ritz

Alto-800

Omni

Eeco

Wagon R

Ritz

Alto-800

26May

Omni

Eeco

Wagon R

Ritz

Alto-800

27 May


12/22

A. TESTER LINE DEFECTS TOP 3 DEFECTS

EECO

S.No. Type of Defect Quantity Department1 CNG Pipe fouling with body/AC pipe 7 AS

2 Clutch pedal play excess/nil 4 AS

3 Headlight Focus Not OK/ Headlight Motor Not OK 4 SQA

Omni

S.No. Type of Defect Quantity Department

1 Headlight Focus Not OK/ Headlight Motor Not OK 50 SQA

2 Accelerator Pedal play excess 7 AS

3 Fuel Pipe fouling with body 3 AS

Ritz


1 Engine Late Start 9 Engine Shop

2 Clutch Pedal Play Excess 6 AS

3 Engine Oil Splash from oil filter 2 AS

YR9


1 Engine RPM High 19 Engine Shop

2 Gear Operation Sticky/Not OK 9 Engine Shop

3 Clutch Pedal Play excess 4 AS


13/22


1. Headlight Focus Not OK/Headlight motor Not OK

0

5

10

15

20

25

Omni

Eeco

Wagon R

Ritz

Alto-800

Reason:

The Headlight defects

are associated with SQA

(Supplier Quality

Assurance).


14/22


2. Engine RPMHigh

0

0.5

1

1.5

2

2.5

Omni

Eeco

Wagon R

Ritz

Alto-800

Model Variant RPM

Omni MPI 900 +/-50

Gypsy MPI 750 +/-50

EECO MPI (Petrol/CNG) 800 +/-50

RITZ Petrol 700 +/-50

RITZ Diesel 800 +/-50

YR9 Petrol/CNG 700 +/-50

YR9 Biofuel 880 +/-50

Analysis of reasons1. Accelerator cable playNill

2. Intake Air Control Valve Pin backup

3. Main harness bent

4. Throttle body problem5. Vacuum pipe out

6. Low Coolant

Engine RPM Standards


15/22

A. TESTER LINE DEFECTS

3. Engine late start

0

0.5

1

1.5

2

2.5

3

Omni

Eeco

Wagon R

Ritz

Alto-800

Analysis of reasons

a. Timing Belt Failure

b. Distributor Failure

c. ECM Failured. Vehicle out of fuel because

of inaccurate fuel gauge

e. Carburetor problem


16/22

B. SHOWER LINE DEFECTS - RESULTS

Defects

0

10

20

30

16-Jun

17-Jun

18-Jun

19-Jun

20-Jun

21-Jun

22-Jun

Trend of Total Defects per day

Model wise bifurcation

Omni

Eeco

Wagon R

Ritz

Alto-800


17/22

B. SHOWER LINE DEFECTS TOP 3 DEFECTS

EECO


1 Rt/Left Sliding door sliding hard 14 AS

2 Back door closing hard 9 AS

3 Rt/Lt Rear Door Opener Play 7 SQA

Omni


1 HMSL Noise 12 AS

2 Rt/Left Door gap not OK 8 AS

3 Rt/Left Door Opening Hard/Sticky 7 AS

Ritz


1 Left/Right Warehousing Level Diff Not OK 3 AS

2 Back Door Gap Not OK 1 AS3 Back Door Catch Noise 1 AS

YR9

S.No Type of Defect Quantity Department

1 Back Door Operation Hard 7 AS

2 Rt/Lt Front Door Glass Rungap not OK 5 AS

3 Alarm Sound Not Working 4 AS


18/22

B. SHOWER LINE DEFECTS - RESULTS

Omni

Eeco

17 June

Omni

Eeco

16 June 18 June

Omni

Eeco

Omni

Eeco

Wagon

R

19 June

Omni

Eeco

Wagon

20 June

Omni

Eeco

Wagon R

Ritz

Alto-800

21 June

Omni

Eeco

Wagon R

Ritz

Alto-800

22 June


19/22


1. Back Door Operation Hard

Frequency

0

2

4

6

8

10

OmniEeco

Wagon RRitz

Alto-800

Frequency

Reason :

This defect is attributed to

Assembly Shop


20/22


2.Sliding Door Play

0

2

4

6

8

10

12

14

Omni Eeco Wagon R Ritz Alto-800

Frequency

Reason:

This defect is also

attributed to

assembly in

Assembly Shop


21/22

QUALITY ASSURANCE : MAJOR DEFECT ELIMINATED.

COST SAVINGS : RECHECKING OF VEHICLES ELIMNATED.

PRODUCTIVITY INCREASE

TIME SAVINGS

FINAL ACHIEVEMENTS OF THE PROJECT


22/22

Thank You ! ! !

Any Questions ?

Analysis of online defects in mass production of automobile

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