STUDY AND ANALYSIS OF PROCESS CAPABILITY OF 4000 TON MECHANICAL PRESS USING 8D METHOD

Presented by: NITHIN J USN: 4JC11MMT09 Under the Guidance of: Dr M S PRABHUSWAMY Professor

Dept of mechanical Engg,SJCE,Mysore

INTRODUCTION

This project aims towards improvement of both product and process by eliminating recurring problems of 4000 ton mechanical press by using 8D method. Forging is a mass production activity. Some of the manufacturing equipments like Mechanical press produce a large number of parts in its running time. Break down of these machines lead to unavailability of these machines there by affecting the process performance in terms of major production loss and also effects quality of the product. To achieve the objective an important problem solving method 2 Eight disciplines of problem solving method can be used.

8D PROBLEM SOLVING METHOD

The 8D Problem Solving (Eight Disciplines) approach can be used to identify, correct and eliminate the recurrence of quality problems.

8D is a problem-solving methodology for product and process improvement. It is structured into eight disciplines, emphasizing team synergy.

The team as a whole is believed to be better and smarter than the quality sum of the individuals.
3

STATEMENT OF PROBLEM

Frequent break downs of 4000 ton mechanical press effects both process and product quality. Therefore there is a need to undertake a permanent corrective action plan to reduce the frequent break downs of this machine .

OBJECTIVES

To carry out Break down analysis of machines.

To prevent root causes and its recurrence.

To establish a permanent corrective action based on statistical analysis of the problem. To improve process and product quality. Using 8D problem solving method
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SCOPE OF THE STUDY

Eight disciplines(8D) of problem solving method has matured into one of the most powerful method used to approach and to resolve problems in industries. 8D method is adopted to identify, correct and eliminate recurring problems and it is useful in product and process improvement. 8D method focuses on the origin of the problem by determining its root causes. Analysis is made to find the causes of the failures and thereby preventing similar break downs. Some of the break downs can be reduced by implementing new ideas through RCM tools like WHY-WHY analysis, fish bone 7 diagram, IS/IS NOT work sheet, Pareto chart etc.,

METHODOLOGY
Literature review about eight disciplines of problem solving method. Preliminary study about production process. Setting the objectives for the study Data collection about machine history. Selection of appropriate tools and techniques for the study. Implementation of team based problem solving method. Finding the root causes for the break downs. Fishbone diagram Why-Why analysis Development of counter measures. Implementation of counter measures. 8 Check the results.

ORIGIN OF THE EIGHT DISCIPLINES CONCEPT

Problem solving is a process, an activity whereby a best value is determined for an unknown, subjected to a specific set of conditions. It is a means by which an individual uses previously acquired knowledge, skills and understanding to satisfy the demands of an unfamiliar situation. The 8D process evolved from Dr. Demings Plan-Do-Check-Act (PDCA) cycle, and the Kepner Tregoe Problem Solving Decision Making (PSDM) process. The U.S. Government first used an 8D-like process during the Second World War, referring to it as Military Standard 1520 (Corrective action 9 and disposition system for nonconforming material).

It was introduced in 1974 and used by the military suppliers until 1995.

The main goal was to indentify errors, make root cause analysis, limitation of waste, prevent reoccurrence, cost reduction and raise the quality

Ford Motor Company first documented the 8D method in 1987 in a course manual entitled "Team Oriented Problem Solving".
Ford later introduced their 8D framework to Motorola in 1989, and required that Motorola used it to resolve all problems involving Ford products 8D methodology has been propagated by Ford on automotive industry and is well known to many companies in the electronics industry. The 8D framework was later adopted by especially the automotive industry in order to solve problems
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4000-TON FORGING PRESS(MECHANICAL PRESS)

Schematic diagram showing the working of forging press

11

Machine Specifications

Rated force : 4000 t Slide stroke : 380 mm Frequency of the slide strokes per min : 55Max Distance between slider and bed : 1380 mm Width of bed under guide lines : 1580 mm Bed dimensions : 1520x1600 mm Slider dimensions : 1450x1440 mm Slider adjustment : 15 mm Working air pressure : 6 atm Overall air expense : 250 l/min Water expense : 13 l/min Width of machine : 4440 mm Overall depth of machine : 4656 mm Overall height of machine : 8570 mm Overall weight (net) : 245 000 kg
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13

14

PIE CHART FOR NUMBER OF DEFECTS OF 1109 STUB AXLE(R5-03)

U/F PIT MARK
77

DAMAGE
S/C FOLD

45

195

QUENCH CRACK LAP BLOCKER

12 4 14
1

15

PIE CHART FOR NUMBER OF DEFECTS OF SUMO VICTA KNUCKLE RH(R5-04)

U/F
96

PIT MARK

DENT
76

DAMAGE S/C

20 48 9 3 3

421

U/S QUENCH CRACK LAP BLOCKER

16

PIE CHART FOR NUMBER OF DEFECTS OF SUMO VICTA KNUCKLE LH(R5-05)

6 14

U/F PIT MARK

88

S/C
218

FOLD

U/S
53

16 75 2

QUENCH CRACK LAP O/H

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PROCESS CAPABILITY FOR STUB AXLE(R5-03)

The allowable thickness dimension for the product is 14+2.5mm for upper specification limit (USL) and 14-0.5mm for lower specification limit (LSL).

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PROCESS CAPABILITY OF R5-03.docx

PROCESS CAPABILITY FOR SUMO VICTA KNUCKLE RH(R5-04)

The allowable thickness dimension for the product is 27+2.5 mm for upper specification limit (USL) and 27-0.5 mm for lower specification limit (LSL).

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PROCESS CAPABILITY OF R5-04.docx

PROCESS CAPABILITY FOR SUMO VICTA KNUCKLE LH(R5-05)

The allowable thickness dimension for the product is 27+2.5 mm for upper specification limit (USL) and 27-0.5 mm for lower specification limit (LSL).

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PROCESS CAPABILITY OF R5-05.docx

Percentage rejection chart of R5-03 due to U/F

12 10

% Rejection

8
6 4 2 0

Jun'12 % Rejection 1.6 TARGET 2

July'12 5 2

Aug'12 8.4 2

Sept'12 6.5 2

oct'12 2.8 2

Nov12 3 2

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Percentage rejection chart of R5-04 due to U/F

12 10

8
% Rejection 6 4 2 0

Jun'12 % Rejection 6.7 TARGET 2

July'12 2.9 2

Aug'12 2.9 2

Sept'12 4.7 2

oct'12 2.5 2

Nov12 1.5 2

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Percentage rejection chart of R5-05 due to U/F

12 10 8 % Rejection 6

4
2 0

Jun'12 % Rejection 2 TARGET 2

July'12 2.4 2

Aug'12 2.8 2

Sept'12 7.2 2

oct'12 0.82 2

Nov12 1.1 2

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D1 - ESTABLISH THE TEAM A small group of people with the process/ product knowledge, allocated time, authority and skills in the required technical disciplines to solve the problem is established and corrective actions is implemented. The team members may be supervisors, quality engineers, technicians, electricians, fitters, welders, helpers etc. In this step of the 8D process following need to be considered: a. Team skills b. Team roles c. Team responsibilities

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D2- PROBLEM STATEMENT

The major frequent problems identified in 4000 ton forging press are: Ram slip problem

Forging Press stroke problem Improper working of top ejection cylinder

Due to these problems of the machine, the product as well as the process is directly affected. 25

D3- DEVELOP THE INTERIM CONTAINMENT ACTION(ICA)

The ICA for the Ram slip in the forging press may be: Ram assembly locking bolts to be tightened with the torque wrench to prevent the problem from spreading.

The ICA for the Forging Press stroke problem may be: Proximity sensor to be checked, sensing limit to be adjusted.

The ICA for the Top ejection cylinder problem may be: Clamping fasteners and seals of ejection cylinder to be checked ,change if necessary.
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D4 - DEFINE AND VERIFY ROOT CAUSE

Root Cause Analysis is a method that is used to address a problem, in order to get to the root cause of the problem.

It is used so that we can correct or eliminate the cause, and prevent the problem from reoccurring.

A Root Cause Analysis will disclose:

Why the incident, failure or breakdown occurred How future failures can be eliminated by: changes to procedures changes to operation training of staff design modifications

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ROOT CAUSE ANALYSIS - PROCESS

Step 1 problem identification

Step 2 Define Problem or Issue

Step 3 Conduct Data Analysis

Step 4 Determine Root Cause(s)

Step 5 Improvement Planning

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Step 6 Evaluate Progress

1. Ram slip problem Cause Analysis: Fish bone diagram

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5 Whys:
Problem: RAM SLIP IN FORGING PRESS

Why

Ram slip in the machine Over load on die Stroke length vary Improper torque setting on adjustment unit Worn out of aluminium liners
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Why

Why

Why

Why

D5- Permanent corrective actions(PCA)

Permanent corrective actions:

Check the over loading condition on the die. Aluminium liners spares must be maintained. Check the condition of the ram adjustment unit, modify if necessary. Aluminium alloys can be used instead of aluminium. Torque must be set properly on the adjustment unit. Periodic alignment of the ram unit to be done once in a week or once in 15 days.
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D6- Incorporation in the system

PM strengthened: Time based maintenance

Point added in PM: Alignment of the ram unit to be checked in weekly Preventive maintenance schedule instead of monthly Preventive maintenance schedule.
Torque on adjustment unit should be min 55 N-m.

One point lesson: Check for over load on the die every day during the start of the first shift by the operator.
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2. FORGING PRESS STROKE PROBLEM

CAUSE ANALYSIS: FISH BONE DIAGRAM

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5 Whys: Problem: Press stroke problem

Why Why Why

Cam setting changed

Cam plate sheared Due to high vibration Machine foundation bolts loose Improper maintenance
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Why
Why

Permanent corrective actions Before starting, check the condition of the machine. Cam unit spare to be maintained. Use of good quality foundation bolts, replace if necessary. Fly wheel bearing condition to be checked regularly. Check and modify the guide clearance. Flush the grease line regularly.

Incorporation in the system PM strengthened: Point to be added in PM: During monthly PM check the machine foundation bolts condition. This increases their life considerably.

Check for the guide clearance (0.4-0.5 mm) in the quarterly PM schedule. 35

3. IMPROPER WORKING OF TOP EJECTION CYLINDER

CAUSE ANALYSIS: FISH BONE DIAGRAM

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5 Whys: Problem: Improper working of top ejection cylinder

Why

Ejection pin not working

Why
Why

Fulcrum lever not working

Rack damaged on ejection unit

i. High air pressure in the ejection cylinder Why ii. Due to burr entry i. Pressure regulator valve not installed Why ii. Poor lubrication
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Permanent corrective actions:

Pressure regulator valve to be installed on the inlet air line. Proper greasing to be done to fulcrum lever and rack and pinion unit. Pressure level in the air line to be set properly, if necessary replace FRL unit. Addition lubrication point to be provided at the of the ejection unit.

Incorporation in the system PM strengthened:

Point to be added in PM: During daily PM check the pressure level (5.5-7 bar) in the air line.

Time based maintenance:

Remove the fulcrum lever and Rack and pinion unit every month, clean it properly, regrease it and again fix it back. Check for proper working of pressure regulator valve on the inlet air line.
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One point lesson: Additional lubrication point to be provided at the point of ejection cylinder unit.

PARETO ANALYSIS

Pareto analysis is a statistical technique in decision making that is used for selection of a limited number of tasks that produce significant overall effect. It uses Pareto principle- large majority of problems (80%) are produced by a few key causes (20%). This technique helps to identify the top portion of causes that need to be addressed to resolve the majority of problems. It is common to refer to pareto as "20/80", under the assumption that, in all situations, 20% of causes determine 80% of problems. 39

Pareto chart for stub axle(R5-03)

250 120

100 200

91
150

95

98.4

99.54

100
80

78
60

Numbers

56
100 40

NUMBERS cum %

50 20

0 U/F BLOCKER LAP DAMAGE QUENCH CRACK FOLD PIT MARK

40

Defects

Pareto chart for sumo victa knuckle RH(R5-04)

450 400 100 350 300 120

94.56 97.51 87.56 76.36 62.18

98.81

99.25

99.69

100
80

250

Numbers

60

NUMBERS
CUM %

200 150 100 20 50 0 0 40

41 Defects

Pareto chart for sumo victa knuckle LH(R5-05)

250 120

200
91.6 150 Numbers 64.6 100 46 80.4 94.9 97.8

100 99 99.4 100 80

60
NUMBERS CUM %

40 50

20

0 42 Defects

FAILURE MODE AND EFFECTS ANALYSIS

FMEA (Failure Mode and Effects Analysis) is a systematic method of identifying and preventing system, product and process problems before they occur. FMEA is focused on preventing problems, enhancing safety, and increasing customer satisfaction. FMEAs are conducted in the product design or process development stages, although conducting an FMEA on existing machinery, products or processes may also yield benefits.
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BENEFITS OF FMEA

Contributes to improved designs for products and processes. Higher reliability Better quality Increased safety Enhanced customer satisfaction Contributes to cost savings. Decreases development time and re-design costs Decreases waste, non-value added operations Contributes to continuous improvement.

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PROCESS FMEA

Process Failure Mode and Effects Analysis (PFMEA) is often developed at the time when a new product or process is being introduced. This activity is very beneficial when ordering tooling and equipment as well as determining process controls. PFMEA is a collection of possible causes and mechanisms for failure modes, as determined by a team. It can also play an important role in day to day improvement and problem solving. 45
PROCESS FMEA.docx

D7- PREVENT RECURRENCE

In this step the team analyses whether the corrective action implemented would prevent or improve the quality of similar products and processes. The changes in the procedures and operations must be communicated to every one.

D8- RECOGNISE THE TEAM

All the efforts made by the team should be recognised and informed to the top level management of the organisation.
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AMW MGM forgings Pvt. Ltd., Preventive maintenance check list of 4000 ton forging press
Sl. No. Activity description Freq Specification Date Observations/ remarks

1
2

Check back lash in press

Check seal condition of clutch & brake Check seal condition of counter balance cylinder Check piston & piston rod condition Check main motor coupling alignment & condition Check any damages / leakages from lubrication line Lubricate bull gear & lay shaft bearings Check conditions at pressure & friction plates of clutch Check conditions of brake pressure & friction plates Check seal condition of counter balance cylinder

Y
Q

Between 1-2 mm
Checked ok

8-02-12
15-04-12

No damage

18-04-12
Added based on history card review

No damage

18-08-12

5 6 7 8 9 10

Q Q H H H H

Alignment done No leakage No sound should come No worn out No worn out No damage

22-08-12 28-08-12 14-06-12 14-06-12 23-06-12 18-12-12

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11

Clean & service lubrication pump

Operate smoothly

18-12-12

Points added after root cause analysis

Sl. No. 1 2 3 Activity description Check for the alignment of the ram unit Check for over load on the die Check torque on the ram adjustment unit Check eccentric shaft bush condition and change if required Check eccentric side bush temp Check guide clearance and condition of guide wear plates Check pressure level in the pressure gauge Check fly wheel side bush temp Check the condition of the foundation bolts and tighten it if necessary Check for top ejection cylinder condition(seals, piston, piston rod, rack & pinion) Freq W W W Specification Checked ok No over load <55 N-m Date 27-03-13 27-03-13 04-04-13

Observations/ remarks

No worn out <65c Should between 0.4-0.5 mm Should between 5.5-7 bar <65c

13-04-13

20-04-13

7 8

D D

20-04-13 21-04-13

Should be tight

03-05-13

48
Q No worn out 16-04-13

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Process capability for 1109 Stub axle(R5-03) after implementation of 8D method

The allowable thickness dimension for the product is, 14+2.5mm for the upper specification limit (USL) and 14-0.5mm for the lower specification limit will (LSL).

49

PROCESS CAPABILITY OF R5-03 AFTER IMPLEMENTATION OF 8D METHOD.docx

Process capability for Sumo victa knuckle RH(R5-04) after implementation of 8D method
The allowable thickness dimension for the product is 27+2.5mm for the upper specification limit (USL) and 27-0.5 mm for the lower specification limit (LSL).

50

PROCESS CAPABILITY OF R5-04 AFTER IMPLEMENTATION OF 8D METHOD.docx

Process capability for Sumo victa knuckle LH(R5-05) after implementation of 8D method
The allowable thickness dimension for the product is 27+2.5mm for the upper specification limit (USL) and 27-0.5 mm for the lower specification limit (LSL).

51

PROCESS CAPABILITY OF R5-05 AFTER IMPLEMENTATION OF 8D METHOD.docx

Percentage rejection of 1109 Stub axle(R5-03) due to U/F after implementation of 8D method
Target 2%
12

10

% Rejection

% Rejection due to U/F TARGET

Jun'12 1.6 2

July'12 5 2

Aug'12 8.4 2

Sept'12 6.5 2

oct'12 2.8 2

Nov12 3 2

Mar'13 2 2

Apr'13 2 2

May'13 2.1 2

52

Percentage rejection of Sumo victa knuckle RH (R5-04) due to U/F after implementation of 8D method
Target 2%
12

10

%Rejection

0 % Rejection due to U/F TARGET

Jun'12 6.7 2

July'12 2.9 2

Aug'12 2.9 2

Sept'12 4.7 2

oct'12 2.5 2

Nov12 1.5 2

Mar'13 2 2

Apr'13 1.71 2

May'13 2.08 2

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Percentage rejection of Sumo victa knuckle LH (R5-05) due to U/F after implementation of 8D method
Target 2%
12

10

%Rejection

0 % Rejection due to U/F TARGET

Jun'12 2 2

July'12 2.4 2

Aug'12 2.8 2

Sept'12 7.2 2

oct'12 0.82 2

Nov12 1.1 2

Mar'13 1.87 2

Apr'13 2 2

May'13 2.1 2

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CONCLUSION

After the analysis it is found that the process is improved and the rejection rate of the component due to Under filling is reduced by using 8D method. Some of the tools of root cause analysis like 5-why analysis, fish bone diagram, pareto analysis are implemented to identify the actual causes of the breakdown. Then some necessary actions was taken to improve the system using root cause analysis and counter measures were developed such that similar type of break downs can be reduced. After the implementation of the 8D method there is a significant 55 increase in the values of CP and CPK .

Product

CP

CPK

BEFORE
1109 Stub axle(R5-03) Sumo victa knuckle RH(R5-05) Sumo victa knuckle LH (R5-05) 0.705

AFTER
2.115

BEFORE
0.624

AFTER
1.957

0.901

2.771

0.818

2.736

0.584

1.976

0.538

1.963

Also after the implementation of the 8D method the rejection rate considerably meets the target value of 2% and ranges from 1.71% to 2.1% between period Mar-13 to May-13. Hence the process and the product can be improved significantly 56 using 8D problem solving method.

THANK YOU