Action Plan of Body 0836-049

Part Name: Body 0836-049

Qty Found NG: 1 Pc. Problem: Thread Damaged, with Major
Dia being observed 9.25 MM.

Problem

A1

Blanking on Traub

A2

Centre-Less Grinding

A3

End-Mill Drilling

A4

Thread-Rolling

Looking at the NG Component it is concluded that such component can be generated at either stage.

A5

Step-Drilling

A6

Chamfer

A7

Flat-Drilling

A8 A9 A10

Re-Threading A11 Free-Hand Drilling Plating Final inspection & Packing

Present Process Sequence

Thread Damaged

The Thread is damaged, wherein the major OD of the component is observed as 9.25 MM.

Only the last couple of threads are in shape with the rest being completely damaged.

Understanding The Problem

A1

Blanking on Traub

A2

Centre-Less Grinding

A3

End-Mill Drilling

A4

Thread-Rolling

A5

Step-Drilling

A6

Chamfer

A7

Flat-Drilling

A8 A9 A10

Re-Threading A11 Free-Hand Drilling Plating Final inspection & Packing

Problematic Areas

Thread-Rolling Operation

Cause And Effect Diagram

MACHINE MAN

Cycle Time Inconsistent

UNSKILLED OPERATOR

Hydraulic Pressure Inconsistent

Roll Alignment Incorrect

Roll Size Incorrect

Stopper Alignment Incorrect

Thread Damaged
Any Dimensional Variation

Surface Finish of the Input Material

Coolant flow incorrect

Rolling Method Incorrect

MATERIAL

METHOD

Fault Analysis (Man)

S. No
1

Potential Cause
Unskilled Operator

Validation
Checked skill status of operator & found upto the desired level, with a clear understanding of the end requirement.

Judgment
Not Valid

Fault Analysis (Method)

S. No
1

Potential Cause
Rolling Method Incorrect

Validation
Observed that the process was correct, as per the industry standards. Coolant flow was correct, and was flowing evenly on the surface

Judgment
Not Valid

Coolant Flow Incorrect

Not Valid

Fault Analysis (Machine)

S. No
1

Potential Cause
Cycle Time (Spark Out) Inconsistent Hydraulic Pressure Inconsistent Roll Configuration Incorrect

Validation
Spark Out Time, timer controlled, and timer working fine. Pressure Controller working fine.

Judgment
Not Valid

Not Valid

Stood correct with regards to the industry standard, and the required Ra Value Correct, was covering the entire surface of the component. Height also correct. Was correct as per the required hardness

Not Valid

Stopper Alignment Incorrect Hardness of the Roll Incorrect

Not Valid

Not Valid

Fault Analysis (Material)

S. No
1

Potential Cause
Variation in the Hardness

Validation
Checked, and found it correct as per requirement.

Judgment
Not Valid

Variation in the Dimensions

Checked, and found it correct as per requirement.

Not Valid

Re-Threading Operation

Cause And Effect Diagram

MACHINE MAN

Cycle Time Inconsistent

UNSKILLED OPERATOR

Die- Size Incorrect

Die-Setting Incorrect

Thread Damaged

Any Dimensional Variation

Re-Threading Method Incorrect

MATERIAL

METHOD

Fault Analysis (Man)

S. No
1

Potential Cause
Unskilled Operator

Validation
Checked skill status of operator & found upto the desired level, with a clear understanding of the end requirement.

Judgment
Not Valid

Fault Analysis (Method)

S. No
1

Potential Cause
Re-Threading Method Incorrect

Validation
Observed that the process was correct, as per the industry standards. However, since the hand pressure is erratic, too much of pressure results in thread damage.

Judgment
Valid

Fault Analysis (Material)

S. No
1

Potential Cause
Variation in the Dimensions

Validation
Checked, and found that the profile of the Input Thread was correct, with the Gauge Qualifying.

Judgment
Not Valid

Fault Analysis (Machine)

S. No
1

Potential Cause
Cycle Time (Spark Out) Inconsistent Die-Size Incorrect

Validation
Spark Out Time, is correct, with the Operator following the required parameters Correct.

Judgment
Not Valid

Not Valid

Why-Why Analysis (FOR OCCURRENCE)

Why Thread flat (major dia. 9.25 observed 9.76 9.96. Because of Thread damage . Because part resting tilted . Because component alignment was disturbed . Because of uneven hand pressure . Because rethreading is a manual process .

Why
Why Why Why Why

Why-Why Analysis (FOR DETECTION)

Why Thread flat (major dia. Oversize ) Because of Thread damage . Setting part mixed with ok parts . Because of Operator lack of awareness .

Why
Why Why Why Why

Thread-Damage

Results showed that it was at the time of Setting, that such NG Piece could get generated. 1. 2. Operators at re-Threading once again trained on how to handle Setting Rejections. Operators at Threading, also proactively trained on how to handle Setting Rejections.

3. Operators at Inspection trained to remove such components.

Analysis & Countermeasure

THANK YOU