Quality Assurance

Wiring Harness Division

 Top Defect Contributors and their Ranks
 Thirteen months Trend Section Wise
 Major Defect Areas (Internal)
 Counter measures for Internal Defects
 Customer Complaints Trend
 Customer Defect Sigma
This Time Special:
 Cutting & Crimping Defects in PPM & New Targets
 Honda Target Monitoring 07-08 & 08-09
 Six Sigma Project in Implement Phase
 Internal Defect Reduction

Measures Taken to reduce

the Internal Defects will be
shared in this presentation.
 Top Five Internal Defects Trend
2 1 1
2627 2449
1796
Circuit 1728
2059 1853
1588
1188
1552
crossed ,open, missing, 1190 1089 1045 919
loose, Short
Apr May June July Aug Sep Oct Nov Dec-08 Jan-09 Feb-09 Mar-09 Apr-09

2733
2797 1 2 3
2653 2686
Taping short / 1935 1769
988
Excess / 568 1121
922 1434
1395
1541

Loose/Miss
Apr May June July Aug Sep Oct Nov Dec-08 Jan-09 Feb-09 Mar-09 Apr-09

Clip/Clamps/Grt. 2187 3
5 4
Direction/Position 1249 1078
278 1091
580
wrong/excess/not 238 721 729
545
291
cut Apr May June July Aug Sep Oct Nov Dec-08 Jan-09 Feb-09 Mar-09 Apr-09
 Top Internal Defects Trend
Month Wise Def ec t Tr end & Rank

Connector Lock 1747 1139 4

1332
Open/Others (Pvc 730
Damage Cover 493 608
215
Crimping) Apr May June July Aug Sep Oct Nov Dec-08 Jan-09 Feb-09 Mar-09 Apr-09

4 3
900 1320
Tube 577 1039 5
641 1023
(V.T/V.S,Cot,Seal,fuse,
381
foam,soldering, sleeve, 404
fuse) missing/NG 262 178
Apr May June July Aug Sep Oct Nov Dec-08 Jan-09 Feb-09 Mar-09 Apr-09

2 1254

Insulator too
short/Wong Cutting
Length 292
Apr May June July Aug Sep Oct Nov Dec-08 Jan-09 Feb-09 Mar-09 Apr-09
 Internal Defects Trend: Cutting
Cutting PPM Trend

1400 500.0
1200
400.0
1000

800 300.0
600
200.0
Target PPM = 73
400
100.0
200

0 0.0
Apr-08 May-08 Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09

Crimping PPM
 Internal Defects Trend: Crimping

Crimping PPM Trend

1600 400.0
1400 350.0
1200 300.0
Target PPM = 118
1000 250.0
Crimping
800 200.0
PPM
600 150.0
400 100.0
200 50.0
0 0.0
Apr-08 May- Jun-08 Jul-08 Aug- Sep- Oct-08 Nov-08 Dec- Jan-09 Feb-09Mar-09 Apr-09
08 08 08 08
 Internal Defects Trend: ECT
ECT Trend: Defects and DPU

6000 0.14

5000 0.12

0.1
4000
0.08
3000
Target = 0.055
0.06
2000
0.04

1000 0.02

0 0
Apr-08 May- Jun-08 Jul-08 Aug- Sep- Oct-08 Nov-08 Dec- Jan-09 Feb-09 Mar-09 Apr-09
08 08 08 08

ECT DPU
 Internal Defects Trend: FVI
FVI Trend: Defects and DPU

7000 0.16

6000 0.14

0.12
5000

Target = 0.075 0.1

4000
0.08
3000
0.06
2000
0.04

1000 0.02

0 0
Apr-08 May- Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09
08

FVI DEF DPU

 April 2009 & Previous Two Months
Circuit Insulator too
(crossed/open/ APR-09 long/Wire APR-09 (WORST FIVE) 100.0
missing/loose/S Stands
1200 100.0
hort) 25%
1100 88.4 90.0
1000
35%
900
80.0
74.0
800 70.0
700 55.6 60.0
600 50.0
500 29.2 40.0
343 310
400
300 216 30.0
169 136 20.0
200
Tube 10.0
100
(V.T/V.S,Cot,Se
Clip/Clamps/Grt. 0 0.0
al,fuse,foam,sol Taping short /

(Corolla)468

(Corolla)464

Rover)507

(Corolla)454

(Corolla)453
Direction/P ositi
dering, sleeve, Excess /

(Land
on
fuse) Loose/M iss
wrong/excess/n
missing/NG 20%
ot cutt
8%
12%

Stage Wise Defect Trend

FEB-09 MAR-09 DPU=0.1136 2793
APR-09
DPU=0.1543 DPU=0.1216 2962
3376 2851
2149

2026
1257

639 622
274
56 23

Cut Crimp ECT FVI Cut Crimp ECT FVI Cut Crimp ECT FVI
 Top Defects: April 2009
Circuit APR-09
Insulator too
(crossed/open/
long/Wire
missing/loose/S
Stands
hort)
25%
35%

Tube
(V.T/V.S,Cot,Se
Clip/Clamps/Grt. Taping short /
al,fuse,foam,sol
Direction/P ositi Excess /
dering, sleeve,
on Loose/M iss
fuse)
wrong/excess/n 20%
missing/NG
ot cutt
8%
12%
 Counter
measures
for
Internal Defects
 Daily Gemba Activity
Daily Report is
discussed.
The Areas with
higher defect rates
are highlighted.
Line leaders are
given the tip for
effective Corrective
Actions.
Daily Gemba Activity
Daily Defects are
discussed with all line
leaders to minimize the
daily defects
 Daily Gemba Activity

Daily Trends are monitored on two different boards.

Minimize the Foam Defects

Paper Sleeves (Recycle)

being used to protect the
foam from transportation
defects
 Wrong Clip Problem

Clip Pictures
posted to ensure
the Correct clip is
used.
 Clip Position/Direction Wrong
Causes Counter Evidence
Measure

Clip loose, changes its workers trained to use

direction and position standard torques for
during handling tightening Clips/
Quality Alert Issued

• Clips in tolerance but

Tolerances on Clip
FVI worker not aware
marked on master
sample

Detailed RCCA of this defect attached with the mail

Quality Alert on all Stations
Training of all team
members on drawing and
view understanding

Color coding provided

on all boards to avoid
wrong insertion.
Taping Loose/Missing/Excess/short
Training on right method of
taping conducted in March
and April 09

QA and Prod staff group

discussion
to build a consensus on
taping defects
 Clip Missing
Causes Counter Measure Evidence

Training Provided.
Operator Missed Clips provided in
the Clips (New packets at Final Assembly
Product
in exact quantities.
understanding
problems) Number of Clips in
packet is equal to the
required number of clips
in harness.
Pictures of each Clip
posted on all boards.
Clip requirement along with direction mentioned on all Boards
 Taping Missing/Excess/short

Causes Counter Evidence

Measure
No Poke-yoke provided.
Mostly on areas where Use of stoppers on
Taping is required assembly board for
between the wires as indicating taping length
no Clamps are installed on all such locations
for indicating taping
length

Variability in Operators Team member with their

responsibilities
including skill sets have
been properly defined
for all set of 2PS
harnesses
Taping Boundary clamps have been introduced
wherever applicable to control the Short and excess
taping.
 Taping Loose
Causes Counter Evidence
Measure
• Excess Handling / Changes in Layout
Excess Product ECT and FVI boards
traveling distance placed next to
conveyors (Honda
Boards and
Conveyors)
Operators have been
• Long waiting time due
re-trained to ensure
to shortages (specific
for 2PS R Cabin Hood No loose taping.
wire).
•Operators have
difficulty with the new
product
 COT Damage
Causes Counter Evidence
Measure

• Excess tightening Operators retrained.

of in order to fix the Clip tightening
clips torque on COT
defined
Improper Torque Instructions posted
employed at each station.
Torque standards for Tyton Guns posted every
where. All JTMs retrained.
 Connector Damage/ Urethane
Foam Damage
Causes Counter Evidence
Measure
• Excess Handling Modifications in
handling method
trolleys now used
instead of shoppers

• Urethane foam is a
delicate part and can Paper covers applied
easily be damaged on urethane foams
because of
environment or during
handling
Additional Pictures for the Corrective measures.
Additional Pictures for the Corrective measures.
 Wrong Insertion
• Location Wise Data Collection for Critical
Assemblies

Root Cause :
Same Color same gage
wires inserted on same
station

Subassembly drawings will be revised to divide such Drawings in two or

more than two drawings: DM Production is working on the project.
Quality Alerts Posted on every single Sub Assembly
Station
 Wrong Insertion
Tags have been introduced to clearly
identify First Off Inspection at Sub
Assembly

• After first off

inspection the sub
assembly is tagged and
acts as sample.
• Tags also ensure that
no station is left for
First off inspection
Taping Loose/Missing/Excess/short

Location No marked on Master

sample for Critical Assemblies.
Location wise data collection at FVI
starts from May
 Clips Position/Direction wrong
Clip requirement along with direction mentioned on all
Boards
 LOCK OPEN
Lock Open Issues
highlighted in the
daily GEMBA
meeting and the
importance of Zero
defects discussed
with all line
leaders.

Quality Alerts
posted showing
OK and NG
condition of Lock
 WRONG CUTTING LENGTH
• Appeared for the first time due to wrong cutting of whole bunch on
KOMAX

Capability Analysis for

KOMAX shows
machine can cut the
wires in a range of
1mm. Operator feeding
values too close to
LCL.
Customer
Care
Date 15 April 2009: WIRE,
Reported INSTRUMENT PANEL (IMV)
History
Wrong Sequence of Connector NIL
Failure Mode
reported

Failure mode Position of two similar color

determined connectors get interchanged Ok Sequence of
by Thal Connector

Immediate Stock checked, Included in PDI

Corrective check point
Action

Done On 15-April-09 Wrong

Sequence of
Permanent Master Sample Changed, Crimped Connector
Corrective scrap wires of similar colors
Action inserted in similar order in
connectors of sample
Done On 15-April-09
Date 28 April 2009: WIRE, ENGINE
Reported HARNESS CIVIC
History
WRONG MODEL ENGINE HARN NIL
Failure Mode DISPATCH
reported 2ZH

Failure mode ENGINE HARNESS OF 2YH MODEL

determined DISPATCHED INSTEAD OF 2ZH
by Thal
2YH
Immediate Stock checked at HACPL and THAL
Corrective
Action
Difference
Done On 28-April-09 in 2ZH and
Permanent For visual identification of harness The 2YH model
Corrective is P-OIL
color of label fixing for 2YH model is
Action Branch
changed to Green
delete in
2ZH
Done On 30-April-09
 Customer Reported Defects & Sigma
Level
Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09
CUSTOMER COMPLAINTS 1 1 2 0 2 2
CUSTOMER DEFECTS 1 1 4 0 3 2
Parts Rejected 1 1 4 0 3 1
HARNESSES SUPPLIED 47305 30888 42078 39525 52123 56932
DEFECT RATIO 2.1139E-05 3.2375E-05 9.5062E-05 0 5.7556E-05 3.513E-05
DEFECTS IN M PARTS 21.1394144 32.3750324 95.0615524 0 57.5561652 17.5648142
DPMO 0.70464715 1.07916775 3.16871841 0 1.91853884 1.17098761
OPPORTUNITIES 1.419150E+06 9.26640E+05 1.262340E+06 1.185750E+06 1.563690E+06 1.707960E+06
PROCESS SIGMA 6.32 6.24 6.01 8 6.12 6.22
Honda Ranking Best Best Best
Middle Best Best Best

PPM = 18
 HONDA PPM Target for Year 07-08
Par t Supply A p r' 0 7 ~ M ar' 0 8 A pr-08

Total Supply 264304 16620

OK Parts 264280 16620
Repair/Rework(In-house& HACP L)
24 0
Par t s Reject ion at 300 150
HA CPL (PPM) Actual PPM: 96
Ta rge t : 1st Ha lf 113 1
200 100
Ta rge t : 2nd Ha lf 85 150

100
50

0
0
0
Ac tual - 84 Ki Apr-0
 HONDA PPM 08-09 AND NEW TARGET
Par t Supply A pr-09

Total Supply A p r' 0 8 ~ Feb ' 0 9 19020

OK Parts o n A ve rag e Basis 19020
Repair/Rework(In-house& HACP L) Actual PPM: 78
0
Par t s Reject ion at 300 75
HA CPL (PPM)
Ta rge t : 50 PPM
200 50 50
Old Target: 150 150

100
25

0
0
0
Ac tual - 85 Ki Apr-09
Honda Rating for the Month
 Customer Complaints – 13 Months Data
(APRIL 2008 – APRIL 2009)

COMPLAINTS
CUSTOMOR MTD YTD
WH CUSTOMER COMPLAINTS (Apr 08- Apr 09)
12
HACPL 1 20
10
IMC 1 10 8
6
SIGMA 0 0
4
HINO 0 0 2
0
PSMC 0 0
Apr- May- Jun- Jul- Aug- Sep- Oct- Nov- Dec-
HACPL Jan- Feb- Mar- Apr-
IMC
DYMCL 0 0 08 08 08 08 08 08 08 08 08 09 09 09 09

TOTAL 0 30

04-08 04-09
DEFECTS
0 2
Customer Complaints & Sigma Level
Customer Defects & Sigma Level (Apr 08 - Apr 09)

10 ∞ 9
8
9 8
8 6.12 6.22 7
7 6
6
Sigma Level = 6.22 5
5 Target Sigma = 6.0
4
4
3 3

2 2
1 1
0 0
Apr-08 May- Jun-08 Jul-08 Aug-08 Sep- Oct-08 Nov-08 Dec- Jan-09 Feb-09 Mar-09 Apr-09
08 08 08

CUSTOMER DEFECTS PROCESS SIGMA

 Customer Complaints & PPM
Customer PPM Apr 08- Apr 09

10 228 250
9
8 200
7 131 143 Target PPM = 69
6 150
5 94
4 64 95 18 100
3
51 58
2 21 32 50
1 0 0
0 0
Apr-08 May-08 Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09

CUSTOMER COMPLAINTS Parts Rejected DEFECTS IN M PARTS

 SIX SIGMA PROJECT
Project Scope:
Cost Saving by reducing wire Lengths in 242L room
main Assemblies
Project Details:
 Length of 49 wires of 242L room main was found excess.
A sample was submitted to IMC where it was installed in
vehicle and the “Fit & Function” was found OK.

Expected Saving:
Saving per Harness : Rs.136/Harness
Monthly Saving (Xli) : Pak Rupees 204,622
Monthly saving (all models): Pak Rupees 409,244

Yearly saving : Pak Rupees 4,910,932

4.9 Million yearly Savings expected
THANK YOU