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Revision 6.34_eng
Quick Response PDCA Assignment / Breakdown Factor Tree Analysis 5 Why Analysis PDCA Check-list
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WHAT IS THE PROBLEM ? > Use 5W + 2H to know what is the Current Situation (C/S) ? CUSTOMER VIEW VALEO VIEW
- What happened? [15] Diaphragm finger tip broken before fitment - What is the difference between good and bad parts? [22] - Was part produced in the standard process? [23] - When was it manufactured at Valeo? [24] - Who manufactured? [25] 1. Bad Part: Crack observed in Diaphragm finger tip 2. Good Part : Finger tip free from crack Yes, Cover Assembly in as per the control plan no: PCA - CP - 011,Diaphragm in Induction hardening line, as per the control plan no: PCA-CP- 653, Cover Assembly - 6/9/2009 No traceability for Diaphragm Cover Assembly - Nagaraj, Velmurugan, Boominathan Induction Hardening - Jaishankar Product is not applicable for other models
Defect quantity
- Why is it a problem? [16] - When detected [17] - Who detected? [18] (name of operator) - Where detected? [19] - How detected? [20] - How many bad parts? [21]
18/09/2009 Assembly Line Operator - TML Assembly Line - TML PCBU Visually 1
- In which other application or processes product is used? [26] - Are we capturing the defect when Yes, Diaphragm finger tip breakage was found in visual reinjecting product in normal process? [27] inspection area. - Did a similar problem happen previously at customer or internally? [28] No, QIM Reference : Q-VT/AmiensFranceAuto20070320-BLN, Q-VT/AmiensFranceAuto-20070404M9L
WHAT DID YOU LEARN from sorting (shift related, period related, operator related)? [35]
1. Customer Consumed all the part in the lot, so there is no immediate segregation in customer end. 2. NG part Cover Assembly was manufactured in 06.09.09 and there is no traceability for the Diaphragm. 3. Diaphragm is hot formed at inhouse. 4. Control Plan no : PCA-CP- 653 verified for tip hardness, it is addressed. 5. PFMEA no: PCP-FM-001 Verfifed for tip hardness it is addressed and checked at 1.First Off, Last Off Per setup. 6. Diaphragm tip hardness is checked in the defective part oberved is 81 HRA against the spec of > 79 HRA 7. Induction hardening line self inspection report verified for last one week of NG Cover assembly batch code production ( 1.09.09 - 06.09.09 ) and QRAP board verfied, no issues addressed. 8. Polymer Concentration checklist verified for last one month and found ok. 9. Cover assembly Self inspection Report verified for 06.09.09 and QRAP board verified, no issues reported.
-Results of sorting in Customer plant -Results of sorting in Transport -Results of sorting in Logistics platform -Results of sorting in Valeo plant -Results of sorting in after-sales stocks TOTAL SORTING
0 0
= = = = = =
----19/09/2009
----RKN
RKN / ND RST / ND MV / SM
Identification OK parts
WHO
DATE
WHERE
THE CUSTOMER CAN DETECT THE DEFECT ON THE PRODUCTION LINE AT 100% : YES
If not, Valeo must set up a control at 100% on the customer line (describe the control made) :
1
AJAY AJAY
19/9/2009 19/9/2009
AVCL AVCL
0.9 0.8
450 400
2. All the Cover Asssembly verified for finger tip breakage by visually
0.4 0.3
0.2 0.1 0 19.09.09 21.09.09 22.09.09
200 150
100 50 0
DATE [41]
LRR
KS
BS
25.07.09
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DATABASE 2 / SHIFT BY MANUFACTURING DATE [42] Date Def. Shift 1 in sorting Def. Shift 2 in sorting Def. Shift 3 in sorting Def. Shift 1 at customer Def. Shift 2 at customer Def. Shift 3 at customer Total qty sorted Shift 1 Total qty sorted Shift 2 Total qty sorted Shift 3 Prod Shift 1 Prod Shift 2 Prod Shift 3 Escaped 1 Escaped 2 Escaped 3 Escaped total 19.09.09 0 0 0 0 0 0 0 467 370 467 370 0 0 0 21.09.09 22.09.09
Revision 6.36_eng
188 0 0 188 0 0
0 0 412 0 0 412
0 0
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PROBLEM DESCRIPTION
LEVEL [2]
4M [3] FACTORS [4]
Level: 1
JUDGMENT CONTROL POINT [5] STANDARD [6] OK PARTS [7] BAD PARTS [8]
Std OK [9] Meet std [10] Direct link [11]
COMMENTS [13]
METHOD Unloading
Component fallen due Improper alignment between loading arm and candle trolly
MATERIAL
Where:Diaphragm Tempering / When:PCA- CP - 755 / 5 Nos. per set up Who: Line operator
44 - 50 HRC
46 48
46 48
MATERIAL
Where:Diaphragm induction hardening / Diaphragm When:PCA-CP- 653 / Finger Tip broken 5 Nos. per set up Who: Line operator Polymer Concentration in Where : Induction hardening Quench OIL coolant
79 HRA min
80 81
79 81
METHOD
3 4
3 3.5
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PROBLEM DESCRIPTION
LEVEL [2]
4M [3] FACTORS [4]
1
JUDGMENT CONTROL POINT [5] STANDARD [6] OK PARTS [7] BAD PARTS [8]
Std Meet OK [9] std [10] Direct link [11]
COMMENTS [13]
METHOD
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By Checking visually
Evidence
[4] Y
Evidence Y
Evidence Y
By dismantling
Evidence Y
Evidence
Evidence Y
Evidence
Evidence
Verification is based on tests, measurements, data to confirm the cause. PUT "Y" (YES) in "Evidence" cell if this is a real cause, put "N" (No) if this is not the real cause
Verification is based on tests, measurements, data to confirm the cause. PUT "Y" (YES) in "Evidence" cell if this is a real cause, put "N" (No) if this is not the real cause
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Evidence
[4]
Evidence Y
How was it verified? 3rd WHY How was it verified? 4th WHY How was it verified? 5th WHY How was it verified ?
Evidence
Evidence
Evidence
Evidence
Verification is based on tests, measurements, data to confirm the cause. PUT "Y" (YES) in "Evidence" cell if this is a real cause, put "N" (No) if this is not the real cause
Verification is based on tests, measurements, data to confirm the cause. PUT "Y" (YES) in "Evidence" cell if this is a real cause, put "N" (No) if this is not the real cause
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ANALYSIS PDCA
Leader: Valeo incident number : R. SEENITAMILVEL Customer Incident number : Date of customer notification : R.KARTHIKEYAN , S.GUNASEELAN(APU), GOPAL(PQ),VELMURUGAN(APU),SURESH,N.DHEENA Opened date & Time: Q-VT/Chennai-AVCL-20090930-KLA 01T/09 19.09.2009 30.09.09
Revision 6.36_eng
Group:
EFFICIENCY CONTROL
0.7 Rejects
Due date [11] Done date [12]
1,Diaphragm TIP hardness found ok. (Measurement: 80 81 HRA , Spec: 79 HRA Min.) 2.Air line crack observed in one diaphragm finger using Magnifying lens.
0.6
0.5
0.4
- IS THE ROOT-CAUSE VERIFIED? [6] Yes, Air line crack observed in one diaphragm finger using Magnifying lens.
0.3
0.2 0.1
WHO [10]
Component fallen due Improper alignment between loading arm and candle trolly
100%
RT / RST
3.10.09
3.10.09
0 M-2 M-1 Actual Situation W+5 days W+10 days W+1 month Target
Lines: Products:
Hotforming line
All Diaphragm
WHO [10]
100%
RST
05.11.09
NO
Customer Sites:
PLANT Manager
Department Manager
QUALITY Manager
CLOSURE DATE
PLANT Manager
Department Manager
QUALITY Manager
DATE
MONTH MAX 1 PERFORM FOLLOW UP AFTER THE IMPLEMENTATION OF [CORRECTIVE ACTION [22
L.R.Rajakumar
S.Venkatesh
S.Balasubramanian
PLANT Manager
Department Manager
QUALITY Manager
DATE
L.R.RAJAKUMAR
S.Venkatesh
S.BALASUBRAMANIAN
27.10.09
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Revision 6.36_eng
PDCA ANALYSIS : EFFICIENCY CONTROL M-2 Rejects M-1 Actual Situation W+5 days W+10 days W+1 month Target 0
EFFICIENCY CONTROL
1
1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 M-2 M-1 Actual Situation W+5 days 0 W+10 days W+1 month Target
#REF! Rejects 0
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CHECK-LIST
Revision 6.36_eng
CHECKS
A [2]
WE
EQUIP MENT
VISUAL AID
DECISION [5]
Y N
Y N
Y N
Y N
COMMENTS [6]
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