PROBLEM SOLVING

What is a problem?
A problem is the GAP between,

The current situation and

Customer satisfaction Defined as discrepancy between an existing standard or expectation and the actual situation

What is problem solving?

8.5.2.1 of TS16949 The organization shall have a defined

process for problem solving leading to

root cause identification & elimination

What is a tool?

Problem solving tools

Flow chart Pareto chart Control chart Tree diagram Check sheet CE diagrams Affinity diagram Matrix diagram Arrow diagram Histogram Scatter diagram Relationship diagram

Matrix data analysis

Decision tree
Capability study

Brainstorming

Core steps of problem solving

1. Define the problem 2. Containment actions 3. Root cause analysis 4. Corrective actions

5. Validate actions
6. Institutionalize or Standardize

1.Define the problem (5W-2H)

1 What What is the problem?

2
3

Who
Where

Who is concerned?
Where does it occur?

4
5

When
Why

When did it happen?

Why is it a problem?

1
2

How
How many

How customer discovered?

How many? (Quantity affected)

2.Containment actions

2.Containment actions
1. See the possibilities of containing the problem at source or immediately after the source 2. Verify the stocks in pipe line for the problem, Customer end, In-transit (between supplier & customer) Work In Progress (WIP) Incoming stage Sub-supplier 3. See other alternates available till problem is solved

3.Root cause analysis

Cause

Effect

3.Root cause analysis

There are several tools available to solve problem and get to the root cause. Their use is dependent upon the complexity of the process, the type of Failure mode, Fit, Function, or Finish, and the system used to measure the specific characteristic that failed which will be attribute or variable data.

4.Corrective actions
List root causes
Think of poka-yoke for root causes

Brainstorm possible solutions and select the most effective, efficient and cost effective solution. Determine if a trial run is needed to confirm and test the proposed solution to verify it is effective and has no other adverse effects.

5.Validate (corrective actions)

Monitor effectiveness of actions (defects occurrence) for three months
If effective, feedback to customer & close If not effective, go back to brainstorming Monitor recurrence for next 12 months (3 months effectiveness + 9 more months)

6.Institutionalize or Standardize
Process flow Work instruct Forms Supplier list PFMEA Procedures Tool drawings Skill matrix Audit plans Control plan Check sheets Product drawings

Past trouble data base

Lessons learnt
Training manual

OJT

What is a QC story?
A past happening which helped QC circles to solve a problem using PDCA cycle, shared to rest of the team as a story to, Motivate other teams Improve knowledge Support to come out of issues

Form a team
Form team comprising personnel from, Caused process,

Production,
Quality & From other process as needed.

Action plan
PROJECT : DIA 3 MM DRILL BREAKAGE IN AVP51 HSG TEAM : Narayanan (Mfg), Gopalan (Mfg), Venkatesan (Mfg), Srinivasan (Mfg), Parandhaman (Mfg), Govindhan (Mfg), Vasudevan (QA) DATE

Date
S.NO TASK RESPONSIBILITY START DATE FINISH DATE JAN FEB MAR APR MAY JUNE JULY

1 2 3 4 5 6 7

PROBLEM (Identify & Define) CONTAINMENT ACTIONS ROOT CAUSE ANALYSIS CORRECTION VALIDATION STANDARDISATION CONCLUSION / EFFECTIVENESS

Mr.Narayanan Mr.Gopalan Mr.Venkatesan Mr.Srinivasan Mr.Parandhaman Mr.Govindan Mr.Vasudevan

Plan

Completed

Pareto of a machined part

PERIOD FROM APRIL TO DECEMBER (9 MONTHS)
225 200 175
QUANTITY

83.54 69.35 52.9

88.87

93.31

100

100

90
80 70

150
125 100 75 50

Total 225 Nos Rejection In 9 Months

60

50
40 30

82

36.44
37 37 32

20

25
0
DIA 3 DRILL BROKEN C V O/SIZE DIA 39 O/SIZE C V DEPTH MORE

12
M8 TAP BROKEN

10
C V UNWASH

15
OTHERS

10 0

Identify the problem

(82 / 225 nos) OF

TOP-1 identified in this case

REJECTION DUE TO DIA 3MM DRILL BROKEN

Top-1 Problem Monetary Loss

PERIOD FROM APRIL TO DEC (9 Months)
100000
RS RS. 77446 COST OF DRILL

50000 0

RS. 16296

TOTAL LOSS = RS. 93,742

Define the problem (5W-2H)

1 2 3 4 5 1 2

Who is concerned?

Production Dia 3 mm drill breaks In Shang-Nong CNC m/c Happens randomly

What happened (or) What is the

problem?

Where does it occur? When did it happen? Why is it a problem? How customer discovered? How many? (Quantity affected)

Contributes significantly for higher rejection

Internal problem 82 nos in 9 months (9 per month)

Data collection for the problem

On the shop (Gemba) Observation

1. BREAKAGE IN NEW AND REGROUND DRILL 2. BURR CLOGGING IN DRILL FLUTE 3. BREAKAGE IN INITIAL CUT AND ALSO IN MORE DEPTH

Brainstorming to generate ideas

TOTAL NO.OF IDEAS GENERATED - 27

IDEAS SHORT LISTED BY TEAM MEMBERS EXPERIENCE AND GEMBA VISIT

- 21

Ideas (Potential causes) Shortlisted-21

SL.NO: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PARAMETER TURRET I NDEXI NG SPI NDLE RUNOUT COOLANT FLOW I MPROPER GRI NDI NG WRONG HANDLI NG WRONG LOADI NG WRONG OFFSET NORMS NOT MAI NTAI NED TOOL GEOMETRY TOOL BEND I NADEQUATE FLUTE LENGTH TOOL GRADE WRONG PROCESS WRONG PARAMETER I MPROPER FI XTURE COOLANT GRADE GRI NDI NG WHEEL GRADE TOOL CLAMPI NG BLOW HOLE PRESENT POOR MACHI NABI LI TY COOLANT CONDI TI ON

Potential causes categorized

MAN
IMPROPER GRINDING WRONG OFFSET WRONG LOADING WRONG HANDLING SPINDLE RUNOUT

MACHINE
TURRET WRONG INDEXING COOLANT FLOW

NORMS NOT MAINTAINED IMPROPER FIXTURE COOLANT GRADE COOLANT CONDITION

GR.WHEEL GRADE WRONG PARAMETER WRONG PROCESS TOOL CLAMPING

DIA 3 DRILL BREAKAGE

TOOL GEOMETRY TOOL BEND WRONG GRADE INADEQUATE FLUTE LENGHT

BLOW HOLE

POOR MACHINABILITY

METHOD

MATERIAL

TOOL

# 1 2

PARAMETER TURRET INDEXING SPINDLE RUNOUT COOLANT FLOW IMPROPER GRINDING WRONG HANDLING WRONG LOADING WRONG OFFSET NORMS NOT MAINTAINED

TOOL VISUAL DIAL VISUAL VISUAL/FEELING SYSTEM SKILL SKILL SYSTEM

CHECK GEMBA CHECK CHECK SHEET GEMBA GEMBA

STATUS SIGNIFICANT SIGNIFICANT SIGNIFICANT SIGNIFICANT INSIGNIFICANT

Initial Validation of Potential Causes

Reduced from 21 Potential to 10 Significant

3 4 5 6 7 8 9 10 11 12

SKILL MATRIX FORM INSIGNIFICANT SKILL MATRIX FORM INSIGNIFICANT TOOL NORMS SHEET INSIGNIFICANT

TOOL GEOMETRY
TOOL BEND INADEQUATE FLUTE LENGTH TOOL GRADE WRONG PROCESS WRONG PARAMETER IMPROPER FIXTURE COOLANT GRADE GRINDING WHEEL GRADE TOOL CLAMPING BLOW HOLE PRESENT POOR MACHINABILITY COOLANT CONDITION

PROFIL PROJ.
DIAL VERNIER BY RESULT SYSTEM STANDARDS DESIGN STANDARD STANDARD VISUAL/FEELING BY CUTTING BY INSPECTION VISUAL

CHECK SHEET
CHECK SHEET CHECK SHEET INSPECTION PROCESS SHEET PROCESS SHEET

SIGNIFICANT
SIGNIFICANT SIGNIFICANT SIGNIFICANT INSIGNIFICANT INSIGNIFICANT INSIGNIFICANT

13
14 15 16 17 18 19 20 21

SYSTEM SYSTEM CHECK SHEET VISUAL REPORT CHECK SHEET

INSIGNIFICANT INSIGNIFICANT SIGNIFICANT INSIGNIFICANT INSIGNIFICANT SIGNIFICANT

Significant Causes (10) Categorized

MAN MACHINE
SPINDLE RUNOUT TURRET WRONG INDEXING IMPROPER REGRINDING COOLANT FLOW

DIA 3 DRILL BREAKAGE

TOOL CLAMPING INADEQUATE FLUTE LENGHT TOOL GRADE TOOL BEND TOOL GEOMETRY

COOLANT CONDITION

METHOD

TOOL

Detailed validation Cause-1

DIA 3 DRILL BREAKAGE TOOL GEOMETRY

TOOL
I.VALIDATION

DIMENSION
POINT ANGLE HELIX ANGLE

SPEC
130 DEG 40 DEG

22.01.02 23.10.02 24.10.02

130 40 129 40 130 41 II.CONCLUSION CAUSE IS NOT SIGNIFICANT

Detailed validation Cause-2

MACHINE
TURRET INDEXING

DIA 3 DRILL BREAKAGE

I.VALIDATION TURRET INDEX STATUS I SHIFT STATUS SHIFT II 22.01.02 OK OK 23.01.02 OK OK 24.01.02 OK OK 25.01.02 OK OK II.CONCLUSION CAUSE IS NOT SIGNIFICANT

Detailed validation Cause-3

MACHINE
SPINDLE RUNOUT

I.VALIDATION
RUNOUT SPEC. 0.01 SPINDLE 1 0.01 SPINDLE 2 0.01 SPINDLE 3 0.01 SPINDLE 4 0.01 SPINDLE 5 0.01 SPINDLE 6 0.01

DIA 3 DRILL BREAKAGE

II.CONCLUSION CAUSE IS NOT SIGNIFICANT

Detailed validation Cause-4

MACHINE
COOLANT FLOW

I.VALIDATION

DIA 3 DRILL BREAKAGE

SPECIFICATION (DISCHARGE) > 10 LPM > 10 LPM

ACTUAL 2.2LPM 2LPM

VARIANCE 7.8LPM 8LPM

II.CONCLUSION CAUSE IS SIGNIFICANT

Detailed validation Cause-5

DIA 3 DRILL BREAKAGE
TOOL BEND

I.VALIDATION

TOOL
T2 0.07 T3 0.04 T4 0.05 T5 0.02 T6 0.08 T7 0.05 T8 0.03 T9 0.02 T 10 0.05

SPEC 0.08 MM

T1 0.02

II.CONCLUSION

CAUSE

5 IS NOT SIGNIFICANT

Detailed validation Cause-6

DIA 3 DRILL BREAKAGE
TOOL GRADE

I.VALIDATION

TOOL
DI
OK (200)

MAKE TITEX

D2
NOT OK (133)

D3
NOTOK (175)

D4
NOTOK (46)

D5
OK (200)

RD ENGG. OK
(200)

OK (200)
NOTOK (105)

OK (200)
NOTOK (113)

0K (200)
OK (200)

0K (200)
NOTOK (52) II.CONCLUSION CAUSE

IT

NOT OK (75)

6 IS SIGNIFICANT

Detailed validation Cause-7

DIA 3 DRILL BREAKAGE
INADEQUATE FLUTE LENGHT
I.VALIDATION

TOOL T2 64.8 T3 65.0 T4 64.6 T5 65.1

SPEC 64MIN

T1 65.2

II.CONCLUSION CAUSE

7 IS NOT SIGNIFICANT

Detailed validation Cause-8

DIA 3 DRILL BREAKAGE
TOOL CLAMPING

METHOD
I.VALIDATION ACCESSORIES STATUS CHECK METHOD

HOLDER
TAPER ADAPTOR COLLET

NO DAMAGES
NO DAMAGES NO DAMAGES NO DAMAGES

VISUAL
VISUAL VISUAL VISUAL II.CONCLUSION

CAUSE

8 IS NON SIGNIFICANT

Detailed validation Cause-9

DIA 3 DRILL BREAKAGE
COOLANT CONDITION

I.VALIDATION

METHOD Day-1 Day-2 Day-3 Day-4 Day-5 NO NO NO NO NO

II.CONCLUSION

FILTERATION SEDIMENT

CAUSE

9 IS NOT SIGNIFICANT

Detailed validation Cause-10

MAN
IMPROPER GRINDING

I.VALIDATION DIMENSION POINT ANGLE HELIX ANGLE SPEC 130 DEG 40 DEG 22.01.02 130 40 23.10.02 129 39 24.10.02 130 40

DIA 3 DRILL BREAKAGE

II.CONCLUSION

COATING OF DRILL AFTER REGRINDING CANT BE DONE

CAUSE

10 IS SIGNIFICANT

Significant Causes
Reduced from 10 to 3
SL.NO 1 2 3 4 5 6 7 8 9 10 PARAMETER TURRET INDEXING SPINDLE RUNOUT COOLANT FLOW TOOL GEOMETRY TOOL BEND IN ADEQUATE FLUTE LENGTH TOOL GRADE TOOL CLAMPING COOLANT CONDITION IMPROPER GRINDING TOOL VISUAL DIAL VISUAL P. PROJECTOR DIAL VERNIER BY RESULT STATUS INSIGNIFICANT INSIGNIFICANT SIGNIFICANT INSIGNIFICANT INSIGNIFICANT INSIGNIFICANT SIGNIFICANT

VISUAL/FEELING INSIGNIFICANT VISUAL P. PROJECTOR INSIGNIFICANT SIGNIFICANT

-

Significant Causes (3) Categorized

MAN
IMPROPER GRINDING

MACHINE
COOLANT FLOW

DIA 3 DRILL BREAKAGE

TOOL GRADE

TOOL

Root Cause-1
MACHINE
COOLANT FLOW

DIA 3 DRILL BREAKAGE

CAUSE 1
COOLANT FLOW

WHY ?
INSUFFICIENT DISCHARGE

WHY ?
LOW CAPACITY PUMP

WHY ?
MACHINE DESIGN

Root Cause-2
DIA 3 DRILL BREAKAGE
2
TOOL GRADE

TOOL CAUSE 2
TOOL GRADE

WHY ?
WRONG TOOL SELECTION

WHY ?
NO AWARENESS

WHY ?

Root Cause-3
MAN
3
IMPROPER GRINDING

DIA 3 DRILL BREAKAGE

CAUSE 3
IMPROPER REGRIDING

WHY ?
NO COATING AFTER REGRINDING

WHY ?
NO FACILITY

WHY ?

Actions for Root Causes

Root Cause-1 Before / After

BEFORE - SHANG NONG
ADVANTAGES OF AMS OVER SHANG NONG
SHANG NONG MACHINE

FEATURES

AMS MACHINE

ADVANTAGE

COOLANT DISCHARGE

20 LTS PER MIN.

2 LTS. PER MIN.

MORE COOLANT / AVOID HEAT

AFTER - AMS

NOZZLE

MULTI NOZZLE

SINGLE NOZZLE

AVOID BURR CLOGGING

NOZZLE DIAMETER

5.5MM

8MM

MORE PRESSURE

PRESSURE

3 BAR

NEGLIGIB LE

FLUSHING BURR EFFECTIVELY

COOLANT TANK CAPACITY

500 LTRS

45 LTRS

MORE COOLANT CAPACITY

PPM COMPARISION - CAUSE -1Coolant flow

3000
2000 PPM 1000 0 MACHINE SHANG NONG AMS 2745 1935

Root Cause-2 Before / After

ACTION : TITEX MAKE TO RD ENGG. MAKE
MAKE TITEX POINT ANGLE 130 DEG. HELIX ANGLE MATERIAL COATING 40 DEG. HSS-CO HSS

RD ENGG. 133 ~ 137 DEG. 35 ~ 37 DEG.

TINAL FUTURA COATING TITANIUM NITRATE

PPM COMPARISION - TOOL GRADE

1935 2000 1500

PPM

1000

410

500
0 TOOL GRADE TITEX RD ENGG.

PPM Trend
REGROUND DRILL

QCC COMPLETED

2500

2000
PPM

2222

1500 1000 500

0

968

878
571 410

JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT

185

Institutionalize or Standardize
# SOP revised (Sop No. 0218 dt. 26.06.02)
# Tooling plan revised.