Step 1.

Definition of A, B
and C Type defects

Role of the operator is most important in Quality

Management.
While working on the machine operator has to be
very alert Whenever the defect is generated operator
has to analyze the phenomenon and write whether it
is A, B or C type of defect. He has to understand with
what action the defect is eliminated.

Not OK

Example for A Type Defect.

Action taken by the operator.

USL

OK

OK

1.Out put is OK initially.

2.Becomes NOT OK.
3.Action is taken by the operator.
4.Becomes OK.

LSL

A type defects are caused by Sporadic Causes.

These defects occur suddenly and will continue till taking
corrective action.
Can be solved through why why analysis.
By taking corrective action the defect can be corrected.
Methodology of solving A Type phenomenon.
Phenomenon

Cause

Countermeasure.

Size variation.

Tool blunt

Provide counter to
facilitate tool changing

Kaizen for Reducing A type defect OD oversize on AS 48.

IDEA: Tool life monitoring
Before

No counter for tool life

monitoring

After

Electronic counter with

Auto machine shut off.

Not OK

Example for B Type Defect.

No Action taken by the operator.

USL

OK

OK
LSL

1.Out put is OK initially.

2.Becomes NOT OK.
3.NO action is taken by the operator.
4.Becomes OK on its own.

Not OK

Example for B Type Defect.

No Action taken by the operator.

USL

OK

OK
LSL

B Type defects are generated due to chronic causes.

These defects generate gradually and disappear itself without taking
corrective action.
By taking countermeasures for all the abnormalities this type of defect can be
corrected.
Methodology for solving B Type defects is PM analysis.

Example of B type defect - On AS 48 machine while checking

the OD of the component continuously one component found
oversize when next component is checked it is found OK.
So without action of the operator the machine is producing ok
component on its own.
We can take practical example of defect OD oversize on AS 48
machine.While continuously checking OD of the components
on AS 48 machine first component is OK. During machining
of the second component chip is trapped between component
and tool so the component is not ok during the third
component no chip is trapped so the component is ok.We have
to do PM analysis of the phenomenon.

Not OK

Example for C Type Defect.

Action taken by the operator.

USL

LSL

1.Out put is NOT OK initially.

2. Action is taken by the operator.
4.Becomes OK. (Setting scrap)

C type defects occurs during set up.

These defects occur in the first product when the set up is done.
By taking corrective action the defect can be corrected.
By providing tool setting master and set up aid this type of
defect can be eliminated.
Methodology of solving C Type phenomenon.
Phenomenon

Cause

Countermeasure.

Size variation.

Wrong setting.

Provide Tool setting master.

Damage.

Measurement error
during setting.

Change analog to Digital.

Kaizen for In-house Rejection C Type Defect : OD oversize

IDEA :Tool setting gauge
Before

No gauge for OD form

tool setting on AS 48
machine

After

Tool setting gauge

provided for OD form tool
setting.

Kaizen for In-house Rejection C type : Lip, undersize

IDEA : Tool setting Gauge
Before

No gauge for Recess tool

setting on AS 48 machine

After

Tool setting gauge

provided for recess tool
setting.

Step 2.
Collecting the data in
A B and C Type from
all the Machines.

QM
Shop:-Rocker Arm Bearing
CELL DEFECT PHENOMENON
20

600
15

15

15

15

15

13

13

15

12

12

12

12

12

12

12

12

12

12

12

12

500

12

12

12

400

284
219

10

201
85

181

199
63

60

52

84

67

29

95

68

46

300

265

230

203

231

200

152

100

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

Defect Phenomenon

30

31

32

33

34

35

36

TOTAL QTY

N o .o f D e f e c t
phenom enon

Machine Defect Phenomenon

8
6
4
2

Defect Phenom enon

2

Defect phenom inon killed

0
Face grinding

OD grinding

ID grinding

Machines
Week

15

Month

16

17

18

Def ect Phenomenon

15

15

15

Kaizen-cumulative
Defect-phe nom e non

20

21

22

23

May-05
15

Defect Phenomenon killed

Sr No

19

Apr -05
15

13

13

24

25

26

27

28

Jun-05

29

30

31

32

33

Jul-05

34

35

36

Aug-05

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

Width Undersize (Face grinding)

76

57

10

15

18

10

96

41

35

46

65

194

Width Oversize(Face grinding)

Parallelism NOT OK(Face grinding)

Burning(Face grinding)

18

OD Undersize( OD Grinding)

22

32

18

19

14

50

79

54

11

17

162

21

11

OD Oversize ( OD Grinding)

OD OVALITY( OD Grinding)

13

Flat mark( OD Grinding)

10

14

14

Burning( OD Grinding)

118

17

10

Burning (ID grinding)

10

12

11

ID Oversize (ID grinding)

11

19

39

48

17

40

15

107

10

41

112

24

84

36

82

22

12

ID Undersize (ID grinding)

13

Taper unequal (ID grinding)

61

40

99

14

Damage mark (ID grinding)

15

ID Chatter (ID grinding)

40

42

93

11

26

14

13

219

85

84

201

199

63

52

60

29

67

95

181

46

203

284

68

230

152

265

231

TOTAL QTY

Step 3.
Forming Team and
Doing kaizen for
killing the defect.

Kaizen for killing defect

Phenomenon for
Rocker Arm

Kaizen Idea Sheet

Activity

KK

JH

QM PM SHE OTP DM ET
M

Loss

'

Result area
Kaizen Theme:-To eliminate the Rejection due to flat mark
On OD grinding machine..

Idea :- From power failure to No power failure

Problem More rejection on OD grinding Countermeasure : To provide UPS for running one Bench mark due to flat mark.
Grinding cycle of Spindle after power failure.
Target -

64
0

Kaizen start -

20/05/05

Kaizen finish
Analysis Why flat mark on OD ?
Due to no rotation of Work piece during
grinding cycle
Why No rotation of work piece?
Due to spindle stoppage.

Results Elimination of scrap due to OD Flat

mark.

21/05/05.

Team MMN,VGR,DDC,UPS

Sustaining Kaizen

Why spindle stops running ?

Due to power failure.
Scope for Horizontal Deployment
S.N.

M/C

Target.

Resp Statu
s.