QC story- Battery mounting

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Mahindra Quality System (A. S.)

Concern Resolution Process for In-house Manufacturing

QC Story

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QC STORY PROJECT

PROJECT TITLE :-Elimination of Battery mounting not done

concern in Alfa Assy line Mahindra and Mahindra Ltd, Zaheerabad Plant, Vehicle PU

Plan Actual

Start Date 08.10.12 18.10.12

Completion Date

04.05.13

Current Status:

CLOSED

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Phase II – QC Story• Team Information• Step1: Select the Theme• Step 2: Justify the choice• Step 3: Understand the current situation• Step 4: Select Targets• Step 5: Analysis (Level 1 Analysis)• Step 6: Implement corrective measures• Step 7: Confirm the Effects• Step 8: Standardise• Step 9: Summarise & Plan future actions• Guidelines to user

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Cross Functional TeamNo Descripti

onName Designation Dept Phone Email

1 Team Leader

K. Vamsi Krishna

Graduate Engineering Trainee

Vehicle PU 8008491307 [email protected]

2 Mentor Mr. Abburi Purna

Asst. Manager Vehicle PU 9676197179 [email protected]

3 Member 1 K Chaitanya Kumar

Asst Manager Vehicle PU 9652262699 [email protected]

4 Member 2 D Suresh Manager Vehicle PU 9949396000 [email protected]

5 Member 3 K Chakravarthy Manager Vehicle PU 9989922011 [email protected]

6 Member 4 Gr suresh Dy. Manager Vehicle PU 9866287959 [email protected]

7 Member 5 Bhanu Prakash Asst Manager SQA 9393315415 [email protected]

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1. Select the Theme

Brief description of Problem

Around of 180 veh per month are reworked in buy-off and hold rework regarding battery mounting.

What: Battery mtg not done

Where: In Alfa (3 wheeler) Mechanical assembly Line.

When : Identified while assembling

Who : Reported by the stage operator and intermediate Buy Off operators

Why :

How: * It got noticed during the inspection at buy off stage * Around of Avg 180 veh per month are reworked in buy-off and hold rework regarding battery mounting.

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2a. Justify the choice (reasons)PARETO OF Battery mtg not done concerns over

PERIOD APR’12 TO Oct’12

• Vehicle loss getting reworked for battery mtg not done : F13 ( High Occurrence)

• High severity rating: 8

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2b. Immediate Containment Action

• Rework for Battery mtg not done will be done at IP buy-off if rework doesn’t complete in time vehicle is reworked at hold rework area.

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3. Understand the current situationProcess flow of Alfa Vehicle on Mechanical Conveyor

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Vehicles get reworked due to Battery mtg not done are around 180 veh /month

Total Vehicle reworked in F-13 (Apr’12 to Oct’12)= 1252 veh

3. Understand the current situation

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4. Select TargetPresent

Level:

Target:

1689 vehicles reworked in F-13( Apr’12 to Oct’12)

Zero Vehicle loss in next months, i.e.from May’13G

OO

D

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5. Analysis 5.1 Identify possible causes:

MACHINE MAN

METHOD MATERIAL

Battery tension rod mtg hole offset

Battery tension rod mtg brkt nut portion bur

Operator Fatigue

Bundy tube fouling to Battery

Tray mtg hole area Dent on Body

operator not followed SOP

inadequate SOP

Tension rod threads not projecting out

Tension rod thread bur/Damage

Gun malfunction

Sealant excess on Battery mtg area

SOP not there

L Bracket bend/ Position Shift

L Bracket miss

Driver seat rod fouling to battery

New operator

Battery tray wrong part

Tray mtg side brkts bend/ Position shiftBattery brkt mtg nut slip

L brkt hole miss

Tension rod mtg hole miss on body

Tray mtg hole miss

Tray mtg bottom extended part to enter body hole operation miss

Tray crack

Tension rod mtg battery brkt hole miss

Tension rod mtg battery brkt hole offset

FRL malfunctioning

SOP key point miss

Tool worn out

Wrong socket used

Wrong nylock nut used

Operator skill

Battery tension rod adjustment not done

Battery NSP on tray

Tray wrong part

Wrong tension rod used for different models

Battery mtg area uneven/major dent

Battery wrong position placed

Wrong battery usage for different models

Battery tension rod mtg brkt bend/twist

Tension rod mtg battery brkt hole undersize

No correct process is defined

Wrong process used in achieving

Battery tension rod mtg brkt nut mtg brkt bend/damage

Battery mtg not done

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5. Analysis

S. No Probable Cause

1 Operator Fatigue

2 L Bracket bend/ Position Shift

3 Tension rod mtg battery brkt hole undersize

4 Tension rod threads not projecting out

5 Bundy tube fouling to Battery

6 Battery tension rod mtg brkt bend/twist

7 Sealant excess on Battery mtg area

8 Tray mtg side brkts bend/ Position shift

Probable Causes: (Based on experience & Knowledge) Eight Probable causes selected out of 44 possible causes for testing i.e. establishing root causes.

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No Probable Cause Testing and Observations Conclusion

1Operator Fatigue

Operator has to take the battery(Wt:15kg’s) from the pallet at certain height and place it on the vehicle as the bending and weight Holding to 140 veh daily leading to fatigue.

Hypotheses valid

5.2 Confirm the probable cause:

5. Analysis

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2

L bracket Bend/Position shift

The L brkt position is getting shifted at the supplier end while L brkt placed in fixture its position is getting shifted while welding the bracket to the body, which in turn leads to the

Tension rod threads not projecting outside the battery mtg bracket hole.

Hypotheses valid


5. Analysis

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3Tension rod mtg battery brkt hole undersize

In mounting the Battery bracket , tension rod may not enter the battery brkt, as its hole is undersize leading the battery mtg not done

Hypotheses Invalid


5. Analysis

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4

Tension rod threads not projecting out

Dimension of the tension rod mtg adjuster rod and plain rod variation leading to tension rod threads not projecting out, leading to Battery mtg not done

Hypotheses Invalid


5. Analysis

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5Bundy tube fouling to Battery

Bundy tubes which is mounted to TMC, in that T-joint mtg bundy tube coming out of the guided side brkts and obstructs the Battery mtg.

Hypotheses valid


5. Analysis

Improper bending profile of the Bundy tube projecting out of the tray stopper and fouling to battery leading to battery mtg not done

Improper bending profile of the Bundy tube projecting out of the tray stopper and fouling to battery leading to battery mtg not done

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6Battery tension rod mtg brkt bend/twist

Battery tension rod mtg Brkt if twisted leads to mtg hole offset and battery mtg not done.

Hypotheses Invalid


5. Analysis

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7


Excess sealant application at the Battery tray mtg area leads to Battery tray NSP, and battery mtg not done.

Hypotheses valid


5. Analysis

Unwanted sealant at the battery tray mtg area leads to tray NSP into its mtg hole and leading to Battery mtg not done hence Hypothesis valid

Unwanted sealant at the battery tray mtg area leads to tray NSP into its mtg hole and leading to Battery mtg not done hence Hypothesis valid

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8

Tray mtg side brkts bend/ Position shift

Battery Tray mtg brackets position shifted leads to Tray not seated properly and bundy tubes projects outside leading to Battery mtg not done

Hypotheses valid


5. Analysis

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5. Analysis

S. No Probable Cause Remarks

1 Operator Fatigue Hypotheses valid

2 L Bracket bend/ Position Shift Hypotheses valid

3 Bundy tube fouling to Battery Hypotheses valid

4 Sealant excess on Battery mtg area Hypotheses valid

5 Tray mtg side brkts bend/ Position shift Hypotheses valid

Following are the Probable causes identified for the conveyor breakdowns


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WHY - WHY Analysis

S. No Valid Probable Cause

WHY WHY WHY

1 Operator Fatigue

Operator has to bend and lift the Battery from the pallet(15 kg’s weight)

Because there is no alternative mechanism, he places manually

Due to the design limitations of the working area

2 L Bracket bend/ Position Shift

Position shifted while welding the brkt to the Body

While welding the Brkts to the body in fixture, twisting of brkt occurs

Due to the fixture limitations while welding Brkts

5.3 Identify the root causes:

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WHY - WHY Analysis

5.3 Identify the root causes:

S. No Valid Probable Cause

WHY WHY WHY

4 Bundy tube fouling to Battery

Bundy tube projecting out of the side brkts and fouling to battery

In design the bending angle and degrees not specified only supplier supplying based on master sample.

Master sample variation at supplier end

5 Sealant excess on Battery mtg area

Sealant provided on the Body as surface at that Tray area as the area is uneven

As the part is welded on the body for supporting

Due to the design

6 Tray mtg side brkts bend/ Position shift

Position shifted while welding the brkt to the Body

While welding the Brkts to the body in fixture, twisting of brkt occurs

Due to the fixture limitations while welding Brkts

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6. Implement the corrective measures6.1 Actions Decided

Root Cause Action Plan Target Dt

Resp. Status

Operator Fatigue

Operator fatigue can be eliminated completely by providing the pneumatic fixture for lifting the battery.

10.01.13GR suresh/

K. ChaitanyaClosed


The bracket shifting is completely eliminated by providing the magnetic surface area over the fixture, which eliminates the brkt position shifting/bend

13.01.13 Sarapu BhanuClosed

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6. Implement the corrective measures

6.1 Actions Decided


Resp. Status


Raised the DCR and corrected the bending profile from 49.52 to 38.87 for avoiding the Bundy tube to contact with tray and Battery

15.04.13 K.vamsi/VGS EN under progress


Permanently delete the sealant application at battery tray mtg area

10.09.12Manikappa/

YSN Murthy

Closed



13.01.13 Sarapu Bhanu Closed

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Root Cause Action Plan Target Dt Resp. Status

Operator Fatigue

Operator fatigue can be eliminated completely by providing the pneumatic fixture for lifting the battery.

10.01.13GR suresh/

K. ChaitanyaClosed


By providing the Pneumatic fixture the operator stress in lifting the battery and placing on vehicle is completely eliminated

By providing the Pneumatic fixture the operator stress in lifting the battery and placing on vehicle is completely eliminated

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Resp. Status





The bracket shifting is completely eliminated by providing the powerful magnet which prevents the brkt shift/Bend during welding to body

The bracket shifting is completely eliminated by providing the powerful magnet which prevents the brkt shift/Bend during welding to body

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15.04.13 K.vamsi/VGS EN under progress


Bundy tube fouling to Tray eliminated by correcting the bending profileBundy tube fouling to Tray

causing to tray crack

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Design change request - DCR

Design change request - DCR

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Permanently delete the sealant application at battery tray mtg area 10.09.12

Manikappa/

YSN MurthyClosed


In order to eliminate the issue of battery tray not fitted in Alfa Model due to sealer bead obstructionWe have taken the below actionConcern: Battery tray Not Fitted due to excess Sealer

PCA: Sealer cutting at Battery Tray BracketCut off No: From 10.09.2012 Second shift vehicles6536-478 ( Alfa Pass ) & 6536-244 ( Alfa L\C)

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The side bracket shifting is completely eliminated by providing the powerful magnet which prevents the brkt shift/Bend during welding to body

The side bracket shifting is completely eliminated by providing the powerful magnet which prevents the brkt shift/Bend during welding to body

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7. Check & confirm the results & effects7.1 Verify Results:

7.2 Full Scale Implementation plan:




15.04.13 K.vamsi/VGS Closed


Permanently delete the sealant application at battery tray mtg area 10.09.12

Manikappa/

YSN Murthy

Closed


The bracket shifting is completely eliminated by providing the magnetic surface area over the fixture, which eliminates the brkt position shifting/bend 13.01.13 Sarapu Bhanu

Closed

After Implementing corrective actions, like tray mtg area sealant deletion, Bundy tube profile correction and gauge correction at supplier end completely resolved the issue.

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7.3 Tangible Benefits

1.Elimination of V1 Concern 2. Improvement in quality indicators (FRC, FBO & DPV)3. Rework cost saved (Avg 180veh/month-Rs. 38,880/- per year)4.Rework at hold eliminated.5.Customer quality increases6. Improved Delivery performance in PDI

7.3 Intangible Benefits

Morale of the operator is increased.

Customer satisfaction increases

7. Check & confirm the results & effects

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8. Standardisation8.1 Updation of documents:

8.2 Training:

8.3 Additional Audit / Check

DCP documents PFC,PFMEA, CP & SOP updated.

Drawings updated.

Process sheets updated.

Concerned operators are made familiar with the system regarding its function, operation

FTG Audit

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9. Summarise & Plan future actions

9.2 Horizontal Deployment:

9.3 Lessons Learnt:

9.1 Conclusion:

By doing the several analysis, concluding the results from analysis the top FBO effecting concern is thrown out completely.

TGR: Implementing corrective actions, like tray mtg area sealant deletion, Bundy tube profile correction and gauge correction at supplier end completely resolved the issue.

TGW: Nil

Horizontal deployment can be applied for all 3-wheeler model manufacturers.

Information shared with HARIDWAR also.

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Thank You

QC story- Battery mounting

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