QC STORY -32 VISION - Creating an Ecosystem for...

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QC Story-1

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On Behalf of Susira Industries Ltd.,

Chennai.

We Welcome the Delegates

for the QCI – DL SHAHNATIONAL AWARDS

ONECONOMICS OF QUALITY

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QC STORY -32 QC Story-1 FACTORY OVERVIEW

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QC STORY -32

SUSIRA INDUSTRIES LTD

QC Story-1 Shop Floor view QC STORY -32

QC Story-1

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 of dependability and social responsibility – in short a company “built to last”.

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QC STORY -32


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QC STORY -32


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QC STORY -32


India’s 1st SME to win 16 National awards for Quality and BusinessExcellence– 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 RecognitionsQC Story-1

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QC STORY -32


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CertificationsQC Story-1

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

QC STORY -32

SUSIRA INDUSTRIES LTD10

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Customers - Prospective

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SUSIRA INDUSTRIES LTD11

QC Story-1 Products

Valve seat InsertsPush rod

Tappets Piston Cooling Nozzle

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QC STORY -32


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QC Story-1

��SUSIRA INDUSTRIES LTD

Presentation on

Reduction in Manufacturing costachieved in Induction Hardening operation through break through machine design Improvement.

QC STORY -32 QC Story-1


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


PLAN

DOCHECK

ACT

1

4

3

2

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Methodology


QC STORY -32

QC Story-1

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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

PLAN

Tool : BRAINSTORMING



List of Problems Identified - Contd

PLAN


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

QC STORY -32

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QC Story-1


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

PLAN


List of Problems Identified - ContdQC STORY -32 QC Story-1

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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PLAN




PLAN

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

QC STORY -32

QC Story-1


PLAN


B Category Problems

1. Low productivity in Induction

Hardening.

2. Less Yield in 961 Push rod



PLAN


C Category Problems

1. Induction hardening Through put

time high

2. Induction Hardening Cost High


GUIDE LINES FOR RANKING

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

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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



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

4Low 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

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Selection of problem through ranking



Top 3 Problems

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QC STORY -32

QC Story-1

Define the selected problem

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1) Low Productivity in Induction Hardening Operation



Present method of Induction Hardening

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Vertical Scanner single end Induction HardeningSUSIRA INDUSTRIES LTD



To Increase Productivity in Induction Hardening Operation.

THEME QC STORY -32

6

QC Story-1 MILE STONE CHARTTo 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

CHECK

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 of

CompletionNo 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 -2008PDCA

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Process Flow DiagramIncoming material inspection

Bar shearing and Cup end Forging

Ball end Forging

CNC Machining

Induction Hardening

Tempering

Inspection & Packing




Current situation

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6972 71

3128 29

0

10

20

30

40

50

60

70

80

July'08 Aug'08 Sep'08

Month

% o

f P

rod

uct

ion

Subcontract Production

In-house Production

QC STORY -32

QC Story-1


Current situation

3.9 4.03.8

3.2

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

Jun'08 July'08 Aug'08 Sep'08

Month

Val

ue

in L

akh

In-house Production


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ANALYSIS OF PROBLEMThrough 4W & 1H

WHAT - Low Productivity in I/H

WHEN - Induction Hardening Operation

WHERE - Induction Hardening Machine

WHO - Passion Team

HOW - By Systematic Analysis & causes


QC STORY -32 Analysis QC Story-1

�SUSIRA INDUSTRIES LTD

BRAINSTROMING POINTS

PLAN

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

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1.1

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2.2

2.1

VALIDATION

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Significant Cause

Significant Cause

Insignificant Cause

Insignificant Cause

QC STORY -32

QC Story-1

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3.1

3.3

3.2

3.1

VALIDATION

3.5

Significant Cause

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ANALYSIS OF PROBABLE CAUSES

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Vital Causes

Action PlanAction PlanAction PlanVital Causes

Less production (800 Nos) per shift at supplier end

Machine Design

Single end Hardening

Problem

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Loading and Unloading Time high

Cycle time high

QC STORY -32

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QC Story-1


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?




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?








Single end

SOLUTION

2.1


manufacturer/market

WHY?WHY?

WHY?




No provision for double end

Machine designed with single end facility


QC STORY -32

QC Story-1



Loading and Unloading Time High

SOLUTION

2.1


manufacturer/market

WHY?WHY?

WHY?




loading one at a timeMachine designed with

single end facility





Cycle Time High

SOLUTION

2.1


manufacturer/market

WHY?WHY?

WHY?




Single end Hardening & loading one at a time

Machine designed with single end facility




SI.No.

Solution Action to be Taken Responsibility & Target Status

Action Plan

1Machine 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

QC STORY -32

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QC Story-1


INTRODUCTION

CFT

B.Monikandan - QAG.Ganesan - MetallurgyR.Sivanesaselvan - MaintenanceP.Dillibabu - ProductionP.V.Ganesan - ProductionP.Muthaiah – HF Technologies(Machine Supplier)S.Kruppaiah – HF Technologies(Machine supplier)



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


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.SUSIRA INDUSTRIES LTD

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QC Story-1Machine Front View


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QC Story-1

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 MEDIA

QC Story-1Validation

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 rate2. Power3. Polymer Concentration.


QC STORY -32

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QC Story-1

Sl# Trial Side Voltage TabFeed rate

Crack Test

Hardness Specification

Hardness Observed in HRC

Case Depth Spec.

Observed Case Depth

Mould No

Micro Structure Result

1 Trial - 1139 Cup

80 2&5 32 Ok 55 - 60 58 - 59 Min

15.0mm17.0 mm 2976

Mainly Martensite with few retained austenite

Accepted

2 Trial - 2139 Cup

80 2&5 33 Ok 55 - 60 58 - 59Min

15.0mm16.50 mm 2977


Accepted

3 Trial - 3139 Cup

80 2&5 32 Ok 55 - 60 58 - 59Min

15.0mm17.0 mm 2979


Accepted

4 Trial - 4139 Cup

80 2&5 33 Ok 55 - 60 57 - 58Min

15.0mm16.50 mm 2980


Accepted

5 Trial - 5139 Cup

80 2&5 33 Ok 55 - 60 57 - 59Min

15.0mm16.50 mm 2980


Accepted

HF INDUCTION HARDENING MACHINE VALIDATION REPORT - CUP


QC STORY -32

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QC Story-1

Sl# Trial Side Voltage TabFeed rate

Crack

Test

Hardness Specificatio

n

Hardness Observed

in HRC

Case Depth Spec.

Observed Case Depth

Mould No

Micro Structure Result

1 Trial - 1139 Ball

80 2&5 32 Ok 55 - 60 57 - 59 Min

15.0mm

16.50 mm

2976Mainly Martensite with few retained

austeniteAccepted

2 Trial - 2139 Ball

80 2&5 33 Ok 55 - 60 57- 59Min

15.0mm

16.50 mm


austeniteAccepted

3 Trial - 3139 Ball

80 2&5 32 Ok 55 - 60 57 - 59Min

15.0mm

17.0 mm 2979Mainly Martensite with few retained

austeniteAccepted

4 Trial - 4139 Ball

80 2&5 33 Ok 55 - 60 57 - 58Min

15.0mm

16.50 mm


austeniteAccepted

5 Trial - 5139 Ball

80 2&5 33 Ok 55 - 60 57 - 59Min

15.0mm

16.50 mm


austeniteAccepted

HF INDUCTION HARDENING MACHINE VALIDATION REPORT - BALL


QC STORY -32

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QC Story-1


Action PlanAction PlanAction PlanComparative study

Before After

QC STORY -32

QC Story-1


Action PlanAction PlanAction PlanComparative 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


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QC STORY -32

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Comparative Graph for results obtained

Production in Induction Hardening machine

69 72 7176

71 7481 83

95100 100

0

1020

30

40

50

60

70

80

90

100

Jul'08

Aug'08

Sep'08

Oct'08

Nov'08

Dec'08

Jan'09

Feb'09

Mar'09

Apr'09

May'09

Month

% o

f P

rod

uct

ion

In house Production

Supplier Production

QC STORY -32

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QC Story-1


Current situation

�� 3.9 4.0

3.8

3.23.4

3.13.4

2.4

0.76

0.35 0.35 0.35

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

Jun'08

July

'08

Aug'08

Sep'08

Oct'08

Nov'08

Dec'08

Jan'09

Feb'09

Mar

'09

Apr'09

May

'09

Month

Val

ue

in L

akh

In-house Production

QC STORY -32 QC Story-1 MILE STONE CHARTTo 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 implementatio10

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 IncreaseProject on

Project No

Meeting Day

PDCA SL#

Identification of Problem(which are unsolved)

PLAN

5

STEPS

CHECK

ACT

06.10.08

2.0 - 3.0 PM

1

2

3

4

DO

6

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Action PlanAction PlanAction Plan��

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�� 1. Productivity Increased from 1200 nos to 6200 nos Per day2. Push rod for Induction hardening Cost Rs.3.03 per push rod saved3. Rs. 227419.00 per month saving4. Rs .27,29,032.00 per year saving5. Subcontracting totally eliminated.

Rs 27,29,032.00 per year

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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.

QC STORY -32

QC Story-1

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Action PlanAction PlanAction Plan��

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�� 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 beenamended.



Horizontal Deployment

1. Double end introduced in Scanner Induction Hardening machine.

QC STORY -32

2. New Induction hardening machine procured with the same concept and spray quench simultaneously

QC Story-1


TOOLS USED

1. Brain Storming

2. Data Collection

3. Flow Chart

4. Cause & Effect Diagram

5. Bar charts

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QC STORY -32

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