Rane Brake Lining Limited

Quality Focus
Schedule A presentation
Presenter :
Sivasankaran. K
Asst Manager - QA

Date : 13th Feb 2017

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 Contents
Expanding Horizons

Background / Challenges

Major Activities
Effects

Future Plans

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Expanding Horizons
Background
90% of supply from Plant-3 is Disc Pad supplied to Passenger Car , Two Wheeler &
Commercial Vehicle.
Supplies to Major OEMs Maruti Suzuki , M&M , Tata Motors, Bajaj, Yamaha thro tier-1
Customers Brakes India Ltd , Endurance, Foundation Brakes Manufacturing Ltd. , and
Brembo Brakes India.
The quality expectation of customers increases year on year.
100% supply of Two Wheeler Disc Pad supplies started from this plant against earlier 75 %
of volume
This plant is having more variant in TWDP & PCDP with similar profile and complex in
nature.
Through lean manufacturing initiatives we have achieved significant results in Productivity,
Quality, Cost & Delivery , but facing challenges to meet customer expectations.
Predelivery Inspection carried out on sampling basis and also skill dependent activity

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Expanding Horizons
Challenges / Issues
High Customer complaints in 2016-17 7 Nos. from OE products
High In process Rejection in 2016-17 6087 PPM
Increase in customer complaint and Customer Line Return. ( from 166 ppm to 530 ppm)
Customer expectations are shifted from Receiving Inspection to Direct On Line (DOL), and
Zero Defect in supplies.
Issue related to pad separation ,wrong thickness & wrong backplate usage in disc pad is
chronic problem
TWDP new product from customer are received in similar construction of backplate
increases more complexity and increase in variant. Traceability & Mix-up issue is concern.
49 Part number varieties of TWDP (Brembo- 27 , ETS 8 , FBML- 2 & After Market- 12 )
with similar profile supplies to different customers.

Hence its imperative to enhance In-process Quality for improving customer quality

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Contents

Background

Major Activities
Effects

Future Plans

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 Alignment of Vision, Goals, Strategies
Vision : To establish global presence and enhance domestic leadership by providing
eco-friendly friction solutions
Goals 2016-21 :
- Sales of Rs. 900+ Crs with international business of 15% on Overall Sales
- ROCE of 25%
- 100% Asbestos Free Company

Strategies

Technology Cost
Customer Focus Quality HR Process
Upgradation Competitiveness

1. Sustain PC and 4. Technology 5. Manufacturing 7. RM Cost 9. Competency

improve improvement process reduction development
CV&MUV projects - Cost improvements and Morale
market share in competitive low cost 8. Total Employee enhancement
OEM formulation & automation Cost reduction
leverage projects
2. Improve market collaborator for
share in North NVH 6. Enhance
and West and technology manufacturing
enhance overall QCD and value
AF product added services
sales - AM

3. Growth in
Export sales
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 Major Activities
Lean Manufacturing Framework

Lean House Customer satisfaction

Improved P,Q,C,D,S,M
Quality Productivity Equipment Manufacturing
Flow Production
improvement improvement Improvement cost reduction
Quality Assurance Cycle time reduction Flexible manufacturing Autonomous Energy cost
Poke Yoke Takt time Set up time Maintenance reduction
FMEA De-bottleneck Multi skill Model Machine Optimized energy
CLIT source
Control charts Line balance Multi models
Abnormality Consumption
Process capability ECRS Common jigs reduction
tagging
Quality audits Leveled production Advance
OPL
First time right Manpower Cellular technologies
optimization Manufacturing
Man-machine Planned
QC Story Yield Improvement
charts Pull Production Maintenance
Methodology Tooling
MUDA elimination PM
Q7, M7 tools Kanban improvement
Layout TBM
DOE, MRA 2 bin system Process
LCA CBM improvement
Autonomation Supermarket
SPF VSM Innovative ideas
Phenomenon
elimination Small lot OEE Improvement
production Loss elimination
Ergonomics
Multi machine
handling

Two Case Study is explained for Phenomenon elimination

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 Major Activities
Lean Manufacturing Framework

Lean House Customer satisfaction

Improved P,Q,C,D,S,M
Quality Productivity Equipment Manufacturing
Flow Production
improvement improvement Improvement cost reduction
Quality Assurance Cycle time reduction Flexible manufacturing Autonomous Energy cost
Poke Yoke Takt time Set up time Maintenance reduction
FMEA De-bottleneck Multi skill Model Machine Optimized energy
CLIT source
Control charts Line balance Multi models
Abnormality Consumption
Process capability ECRS Common jigs reduction
tagging
Quality audits Leveled production Advance
OPL
First time right Manpower Cellular technologies
optimization Manufacturing
Man-machine Planned
QC Story Yield Improvement
charts Pull Production Maintenance
Methodology Tooling
MUDA elimination PM
Q7, M7 tools Kanban improvement
Layout TBM
DOE, MRA 2 bin system Process
LCA CBM improvement
Autonomation Supermarket
SPF VSM Innovative ideas
Phenomenon
elimination Small lot OEE Improvement
production Loss elimination
Ergonomics
Multi machine
handling

One Case Study is explained for Poke yoke

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 Major Activities
Case Study 1: Poka Yoke in Printing machine for Thickness issue

Issue:
Thickness undersize / Taper Grinding of four wheeler disc pad
Observation :
Thickness undersize / Taper Grinding of the four wheeler alto disc pad is
cannot be detected in subsequent stages after grinding process

Action taken:
Thickness checking potentiometer is fixed in the printing process
Thickness of the pad is sensed by potentiometer sensor 100% in the
conveyor .On the variation of thickness ,conveyor belt interlocked to
stop sending the pad for printing stages
If any defected pad in potentiometer it will stop the conveyor and
makes an alarm light with buzzer

Results:
Thickness undersize Detection improved
Customer complaint regarding thickness issue
eliminated
Customer requirement satisfied
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 Major Activities
Lean Manufacturing Framework

Lean House Customer satisfaction

Improved P,Q,C,D,S,M
Quality Productivity Equipment Manufacturing
Flow Production
improvement improvement Improvement cost reduction
Quality Assurance Cycle time reduction Flexible manufacturing Autonomous Energy cost
Poka Yoke Takt time Set up time Maintenance reduction
FMEA De-bottleneck Multi skill Model Machine Optimized energy
CLIT source
Control charts Line balance Multi models
Abnormality Consumption
Process capability ECRS Common jigs reduction
tagging
Quality audits Leveled production Advance
OPL
First time right Manpower Cellular technologies
optimization Manufacturing
Man-machine Planned
QC Story Yield Improvement
charts Pull Production Maintenance
Methodology Tooling
MUDA elimination PM
Q7, M7 tools Kanban improvement
Layout TBM
DOE, MRA 2 bin system Process
LCA CBM improvement
Autonomation Supermarket
SPF VSM Innovative ideas
Phenomenon
elimination Small lot OEE Improvement
production Loss elimination
Ergonomics
Multi machine
handling

One Case Study is explained for FMEA

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 Major Activities
Case Study 1: FMEA review in Power cut issues
Issue:
Potential failure mode of pad separation in customer end
Observation :
Power cut during venting in curing process
It tends to reduce the pressure acting on the pads
Pad separation pad
Cycle abort before completion of cycle time

Action taken:
Other than rejection separate Blue box identified Power cut with lock
and key is provided in all the curing machine
Collected power cut pads are subjected to 100% proof load test to
ensure the sufficient bonding strength of the cure pads

Results:
Failure mode of pad separation in customer end is eliminated
Bonding strength ensured in starting stage itself.
Customer satisfied with this process.
RPN number reduced from 144 to 80
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 Major Activities
Lean Manufacturing Framework

Lean House Customer satisfaction

Improved P,Q,C,D,S,M
Quality Productivity Equipment Manufacturing
Flow Production
improvement improvement Improvement cost reduction
Quality Assurance Cycle time reduction Flexible manufacturing Autonomous Energy cost
Poke Yoke Takt time Set up time Maintenance reduction
FMEA De-bottleneck Multi skill Model Machine Optimized energy
CLIT source
Control charts Line balance Multi models
Abnormality Consumption
Process capability ECRS Common jigs reduction
tagging
Quality audits Leveled production Advance
OPL
First time right Manpower Cellular technologies
optimization Manufacturing
Man-machine Planned
QC Story Yield Improvement
charts Pull Production Maintenance
Methodology Tooling
MUDA elimination PM
Q7, M7 tools Kanban improvement
Layout TBM
DOE, MRA 2 bin system Process
LCA CBM improvement
Autonomation Supermarket
SPF VSM Innovative ideas
Phenomenon
elimination Small lot OEE Improvement
production Loss elimination
Ergonomics
Multi machine
handling

One Case Study is explained for Process capability

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 Major Activities
Case Study 1: Low Process Capability for Two wheeler Disc pad Flatness in Shot Blasting
machine
Issue:
Flatness of two wheeler disc pad is inconsistent in final
products
Observation :
Short term Capability(Ppk) observed 0.77 against the
requirement of >1.33
Inconsistency observed in plates flatness after grit
blasting

Action taken:
Conveyor feed rate of grit blasting machine changed from 4.7
Hz to 6 Hz to make the consistency in flatness of back plate
after grit blasting itself

Results:
Short term Capability Ppk improved from 0.77 to 1.63
Consistency in flatness of two wheeler products

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 Major Activities
Lean Manufacturing Framework

Lean House Customer satisfaction

Improved P,Q,C,D,S,M
Quality Productivity Equipment Manufacturing
Flow Production
improvement improvement Improvement cost reduction
Quality Assurance Cycle time reduction Flexible manufacturing Autonomous Energy cost
Poka Yoke Takt time Set up time Maintenance reduction
FMEA De-bottleneck Multi skill Model Machine Optimized energy
CLIT source
Control charts Line balance Multi models
Abnormality Consumption
Process capability ECRS Common jigs reduction
tagging
Quality audits Leveled production Advance
OPL
First time right Manpower Cellular technologies
optimization Manufacturing
Man-machine Planned
QC Story Yield Improvement
charts Pull Production Maintenance
Methodology Tooling
MUDA elimination PM
Q7, M7 tools Kanban improvement
Layout TBM
DOE, MRA 2 bin system Process
LCA CBM improvement
Autonomation Supermarket
SPF VSM Innovative ideas
Phenomenon
elimination Small lot OEE Improvement
production Loss elimination
Ergonomics
Multi machine
handling

One Case Study is explained for Phenomenon elimination

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 Major Activities
Case Study 1: Temperature Variation in Two wheeler Disc pad Module

Issue:
Temperature variation in curing process
Observation :
Scale formation in-between the punch and the bottom
middle plate
Scaling restrict the heat transfer between punch and
middle plate

Action taken:
Mould RM frequency changed from one month to 15 days for
running mould
Monitoring thermocouple planned to detect the occurrence

Results:
Cracks in IPR reduced.
Scrap reduced.

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 Major Activities
Result Plant IPR
20000

BETTER
PPM

10000

0 2011- 2012- 2013- 2014- 2015- May- Jun- Aug- Sep- Nov- Dec- Feb- Mar-
Apr-16 Jul-16 Oct-16 Jan-17
12 13 14 15 16 16 16 16 16 16 16 17 17
Result 8607 8522 18920 7934 6011
Target 5875 5875 5875 5750 5750 5750 5625 5625 5625 5500 5500 5500
Actual 6537 6005 6077 6038 6057 5422 6299 6177 6165
Cumm 6537 6260 6164 6123 6101 6019 6061 6076 6087

IPR reduced from 6537 PPM to 6087 PPM

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Contents

Background
Major activities
Effects
Future Plan

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 Effects

Customer Line Rejection CLR C

2000
Better
1500
Before After
PPM

1000

500

0
2012- 2013- 2014- 2015- 2016- 2016- 2016-
13 14 15 16 17 Q1 17 Q2 17 Q3
Target 1000 500 250 400 125 100 75
Actual 1356 482 1428 185 881 739 1

Customer line rejection (CLR-C) reduced

from 881 PPM to 1 PPM ( Sep 16 to Dec 16 )

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 Effects

Brakes India Customer Rating From Portal

600

500

400
PPM

300

200

100

0 2011- 2012- 2013- 2014- 2015- Apr- May- Jun- Aug- Sep- Oct- Nov- Dec- Jan- Feb- Mar-
Jul-16
12 13 14 15 16 16 16 16 16 16 16 16 16 17 17 17
Result 800 69 51 8 185
CLR!#REF! 1
Actual 0 0 0 0 0 0 2 0 0
CLR!#REF! 1

2 PPM for Customer Line Rejection (Apr16 to Dec16)

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 Effects

Brembo Customer Rating From Portal

34 PPM for Customer Line Rejection (Sep16 to Dec16) 20 of 37

 Effects
FBML Customer Rating From Portal

0 PPM for Customer Line Rejection & 100% for Supplier Quality Rating (Apr16 to Dec16)
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Contents

Background
Major activities
Effects
Future Plan

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 Future Plan
Achieve zero customer complaints & Customer Line Rejection
< 100 ppm.
Achieve In-Process Rejection < 5000 PPM
Improve Customer Rating for award winning
Detection of pad separation by non destructive method of
ultrasonic method. For that we need huge support from top
management
Electronic TPL checking gauge to ensure the TPL of the
product

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Rane Brake Lining
Rane Brake Limited
Lining Limited

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 Major Activities

Printing Stage

Before After

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 Major Activities
Detection Machine Relay Logic:
Activity during pad Warnin
S.No Conveyor Buzzer Printing
loading in chute g Light

1 Pad (Ok) loaded Runs Runs

2 Pad sensed Runs Runs

Second (Not Ok)

3 Runs Runs
pad loaded

4 Second pad sensed Stops Glows Beeps Stops

Third (Ok) pad In stop In stop

5 Glows Beeps
loaded position position

In stop In stop
6 Third pad sensed Glows Beeps
position position

Potentiometer range set at 14.5 / 14.8

From above logic, if the pad is detected NG in potentiometer
conveyor stops immediately preventing the pad moving to printing

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 Major Activities
Detection Machine Trails

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 Major Activities
Detection Machine Effectiveness:

THICKNESS MEASURING LOCATION BY POTENTIOMETER

A B

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 Major Activities
Power Cut simulation Trail:
1st Vent 4th Vent
Shear Value In Kgf (Spec Shear Value In Kgf
Cavity No Cavity No
681 Kgf) (Spec 681 Kgf)

1 148 1 177

2 189 2 188
169 3 191
3
188 4 169
4
158 5 188
5

Shear load not meeting the specification and 100 % BMV Observed
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Major Activities

Power cut Pads100 %

Proof load checked

Power cut and delay load pad

put in Blue Box

Defective sample Detected by

Proof Load test 30 of 37
Major Activities

RPN Reduced from 144 to 80

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 Major Activities
Before Improvement - Short term Process Capability study for Flatness
of Two wheeler Disc Pad

Expected
Ppk is 0.77 which is less than the requirement Rejection is 21040
PPM 32 of 37
 Major Activities
Expanding Horizons

Flatness at Various processing stages Incoming back plate

Boxplot of Back Plate, After Grit B, After Curing, Afetr Baking, ...
0.5
After Grit Blasting

0.4
After Curing

0.3
After Baking
Data

0.2
Upper specification Limit Final Product

0.1

Lower specification Limit

0.0
Back Plate After Grit Blasting After Curing Afetr Baking Final product
After QIT Study we
optimized the above result
Increase in flatness after grit blasting .

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 Major Activities
After Improvement - Short term Process Capability study for Flatness of
Two wheeler Disc Pad

Expected
Rejection is 0.59
Ppk is 1.63 which is meeting the requirement PPM 34 of 37
 Major Activities
Before & After Improvement - Process Capability

Before After
Ppk 0.77 1.63
Existing Process Modified Process

0.07 mm 0.07 mm
Convex Convex

0.40 mm 0.15 mm
Concave Concave

0.10 mm 0.05 mm
Concave Concave

0.08 mm 0.06 mm
Concave Concave

0.12 mm 0.05 mm
Concave Concave 35 of 37
 Major Activities
Temperature variation between cavities - Case-1
DPO 515 DDL Cure machine

Mould temperature
monitored by Data
logger

Mould bottom plate temperature 206oC

Punch temperature - 153oC ~ 170oC

Scale formation
Counter measure
Root Cause between punch & 1. Mould RM frequency changed from one month to 15
bottom plate days for running mould
2. Monitoring thermocouple planned to detect the
occurrence

Result

Scale formation in between punch & bottom

plate contributes the temperature variation
Mould bottom plate temperature 168oC
Punch temperature - 153oC ~ 157oC

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 Major Activities
Expanding Horizons

Defect phenomena Elimination for Temperature Variation

Sno What What When Who How Remarks

To provide interlink
to avoid machine
Curing Temperature Low and High
1 Nov 16 PED running during Completed
Process in curing machine
controller and
Heater failure

Before

After

Temperature actual
Top and Bottom mould
reading displayed
Addition thermocouple
in controller
provided
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