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BY
CHENNAI TIGERS
RNAIPL
BODY LINE #
1
RAJAGOPAL
Facilitator
VASU
Sub Leader
RAMUKUMAR
Team member
P
KARUPAN
Team
member
KARTHIK
Team member
MUTH
U
Team member
<Shop >
Body # 1
>
THEME SELECTION :
QC THEME SELECTION BASED SUBFLOOR AOP KPI
FSTR TARGET ( April15 ~ MARCH 16 )c
100
STR
TARGET %
100
100
90
80
70
60
50
94
98
97
96
40
30
1.
20
10
0
2.
3.
TARGET -100%
ACTIVITY SCHEDULE
100.0
95.5
90.0
89.8
100
80.0
80
75.0
70.0
60.0
59.1
60
50.0
40.0
38.6
40
34
30.0
Axno of cocern
20
20.0
18
14
13
10.0
5
4
0.0
percentage
77
6
NO OF CARS
QC ACTIVITY
START
G
O
O
D
3
2
1
0
DEC'14
JAN'15
FEB'15
MAR 15
Month
APRIL'15
MAY'15
JUNE 15
QC CIRCLE THEME
<Shop >
Body # 1
>
8
6
DPU
2
0
april'15
MAY'15
Month
JUNE 15'
JULY 15'
Grade defination
Judgement grade
Defination
V1
Concerns
VES definition of body
where all
customer
dissatisfied
& claim for
repair
V2
V3
Most of
customers
point out in
questionnair
e in survey
Some
customers
aware of
quality but
most of them
accept
BRAIN STORMING
CIRCLE MEMBERS
VOTING
1.RAMKUMAR
2.KARTHICK
3.MUTHU
4.PKARUP
5.VASU
6. Factor Analysis
1
MAN
MACHINE
METHOD
Stud collet
carbon deposit
OTHERS
Stud Gun
parameter
Stud strength
confirmation not
done
RR ABS Cover
M6 Stud Failure
Oil Contamination)
Low Awareness
Stud weld
Process
parameter and
equipment
concerns
MATERIALS
4M
Main Factors
MAN
SKILL LEVEL
MAN
KNOWLEDGE
MACHINE
MACHINE
METHODS
METHODS
STUD GABARI
MATERIAL
WHY
WHY
WHY
1. STUD WELD
CYCLE NOT
COMPLETE
GUN ANGLE
NOT
MAINTAIN
OPERATOR NOT
AWARE OF
PERPENDICULARI
TY
STUD GUN
USAGE IN
ANGULARTIY
SWITCH
DEACTIVATED
MODE
2. STUD WELD
CYCLE NOT
COMPLETE
DEFECTIVE
DROP DOWN
TIME
STUD GUN
ROUTING
IMPROPER
3. STUD WELD
CYCLE NOT
COMPLETE
LIFTING OF
GUN BEFORE
PROCESS
COMPLETION
LACK OF
AWARENESS ON
STUD WELD
INTGERITY
HIGH SPEED
STUD GUN
HANDLING
WHY
VERIFICA
TION
RESULT
SOLUTIO
N
OK AS PER
STANDARD
-STUD GUN
ELONGATION
ON OPPOSITE
Direction
OK AS PER
STANDARD
NG- RESULT
FOUND NG
AWARENESS
TRAINING ON
STUD WELD
INTEGERITY
AND STUD
WELD GUN
HANDLING
Significant
Key factor: High speed weld Gun handling
leads to weld cycle incomplete
Not significant
WHY
WHY
1. STUD GUN
COLLET AND
FLASH
SHEILD
WORN OUT
HIGH
CARBON
SPATTER
DEPOSIT
ON THE
COLLET
AND FLASH
SHEILD
COLLET/FLASH
SHEILD
CLEAING DONE
2 TIMES PER
SHIFT
NG: STUD
FAILURE
OBSERVED
REVISION
FOR STUD
COLLET
/FLASH
SHEILD
CLEANING
FREQUENCY
(1HRLY
ONCE)
2. STUD
WELD GU N
PARAMETER
STUD WELD
GUN
CURRENT
PARAMETER
VARIATION
DROP OF
CURRENT
DURING STUD
WELD PROCESS
OK AS PER
STANDARD
NO Current
variation
observed
STUD WELD
GUN
ANGULARIT
Y
BYPASSED
FEED BACK
SIGNAL NOT
PROPER
RESULTING IN
ERROR GREEN
LIGHT NOT
GLOW
NG: FLAT
NESS FOUND
UNEVEN
TO BE FOR
UNEVEN
FLAT NESS
IN PART
DESIGN
LEVEL
3. STUD GUN
90 DEGREE
ANGULARITY
SETTING ISSUE
EARTHING
WHY
STUD GUN
BASE PANEL
PROFILE
UNEVEN IN
FLAT NESS,
WHY
PROFILE
FLATNESS
VARIATION
VERIFICA
TION
RESULT
SOLUTIO
N
FACTOR VERIFICATION :
Significant
Trial part
Not
significant
WHY
WHY
1. STUD
GABARI TO
BASE PANEL
GAP
HIGH
THICKNESS
OF STUD
GABARI
STUD GABARI
FRP MATERIAL
THICKNESS
HIGH
2.STUD
GABARI TO
BASE PANEL
GAP
MANUAL
CLAMPS
IMPROPER
LOCKING
MANUAL CLAMP
WORN OUT
WHY
CURVE
PROFILE
GABARI NOT
SEAT WITH
PANEL:HIGH
GAP
WHY
VERIFICA
TION
RESULT
OK AS PER
SOP
NG: EXCESS
GAP FOUND
AFTER
CLAMPING
SOLUTION
STUD
GABARI
DESIGN
NEED TO
CHANGE MS
STEEL.
MODIFICATI
ON TO BE
DONE
PNEUMATIC
CLAMPS TO
BEIMPLEME
NTED
FACTOR VERIFICATION :
Significant
Gabari Improper locking manual clamp play
creating Gap , More force need to exert on
Gun .Stud failed during strength check
Not significant
WHY
WHY
1.
MATERIAL
:OIL
CONTAMINATI
ON(REAR
FLOOR REAR
MBR CROSS)
OIL
CONTAMINA
TIO IN
RECEVING
LEVEL
2. PANEL
PROFILE FLAT
NESS
/CONCERN IN
REAR FLOOR
REAR MBR
CROSS
PANEL
PROFILE
FOUND
FLAT NESS
FOUND
VARIATION
SPOT
UNDULATION
INCOMING PART
WHY
WHY
VERIFICA
TION
RESULT
SOLUTIO
N
OK AS PER
STANDARD(
NO excess
oil)
SPOT
LOCATION
SHIFT FROM
IN PART
2 SPOTS
LOCATED IN
STUD WELD
LOCATION .
NG:PROFILE
FLATNESS
UNEVEN DUE
TO SPOT
UNDULATION.
1. STUD
FAILURE
OBSERVED
ON STUD
WELDED
ABOVE THE
SPOT
2. STUD WELD
GUN
ANGULARIT
Y SETTING
CONCERN
MATERIAL
DESIGN TO
BE CHECKED
AND SPOT
LOCATION
CHANGES TO
BE DONE AS
PER DESIGN
FACTOR VERIFICATION :
Significant
1. Profile Found uneven, Due to Spot
mislocation and Uneven Interference
Not significant
FACTOR VERIFICATION :
Significant
Excess oil leads to stud failure.No Excessoil
found in part
Not significant
ASSUMED MAIN
FACTORS
1
Man :Working
skill
M
A
I
N
CAUSES
FESABIL
ITY
CHECKI
NG
a)High speed
stud gun handing
leading to weld
cycle incomplete
1. Lack of awareness
on stud weld
integrity .
2. Lack of awareness
on high speed
working impacts on
stud welding
YES
Machine :Stud
Gun Angularity
a.Stud Gun
angularity 90
degree setting
Concern
YES
Method :Manual
clamp Concerns
and Stud Gabari
Bush Loosening
and play
a. Manual Clamps
application
and Stud
Gabari Bush
Design
concerns
1. Pneumatic Clamps to be
implemented for improving
rigidity in stud Gabari
clamping .
2.Stud Gabari Abs cover
design to changed from FRP
to Cast iron to improve
YES
F
A
C
T
O
R
V
E
R
I
F
I
C
A
T
I
O
ANALYSIS AND
VERIFICATION ITEMS
M
A
I
N
ANALYSIS AND
VERIFICATION ITEMS
CAUSES
IMPROVEMENT ACTIONS
PROPOSED
FESABILITY
CHECKING
Method
:Manual
clamp
Concerns in
stud fixture
a. Manual Clamps
application
Concernns
1. Implementation of
Pneumatic clamps to
improve for
improving the
holding of clamps.
2. Improves in one
switch even locking
and unlocking of
clamps s
YES
Machine
:Stud weld
collet
concerns
YES
Material: RR
Side mbr
Lower Assy
Cross part
LH/RH
a. Material base
profile uneven
for stud head
positioning
YES
F
A
C
T
O
R
V
E
R
I
F
I
C
A
T
I
O
N
ASSUMED MAIN
FACTORS
Stud Welding
Fixture
Before Condition
After Condition
Manual Clamping
Operation in Stud
Fixutre
Stud Welding
Fixture
Before Condition
After Condition
FRP TO CAST
IRON
FAILURE MODE
ANALSYIS
:TEAM
HIGH SPEED STUD GUN HANDING
IMPACTS
KEY LEARNINGS
KEY LEARNING
17.04.15
Causes
1.Supplier spot shifted and welded in stud weld location creating poor weld current penetration
during stud welding.
2.Spot location variation found part to part.
3.Stud Getting failure during mallet check leading to process delay.
4. Stud weld Gun angularity setting not able to maintain due to uneven profile due to spot impression.
5.Day wise 6 cars get failure during stud strength check .
Temp action:100% mallet check in process and quality gate to prevent out flow
Perm action :Supplier spot need to shift 20mm from current position (PQA Team/Body PE)
Stud Welding
Fixture
Before Condition
After Condition
4M CHANGE
IMPLEMENTATION
IN MATERIAL
1. MATERIAL SPOT
INTERFERNCE IN STUD
LOCATION
2. FREQUENT STUD FAILURE
ON THIS LOCATION
1. MATERIAL 4M CHANGE
IMPLEMENTATION IN SPOT
SHIFTING DONE IN
INCOMING PART .
2. ACTION IMPLEMENTED AT
SUPPLIER END BY DESIGN
TEAM
Stud Welding
Fixture
Before Condition
After Condition
4M CHANGE
IMPLEMENTATION
IN MATERIAL
RESULT CHECK
77
6
NO OF CARS
QC ACTIVITY
RESULT
G
O
O
D
3
2
1
0
JAN'15
FEB'15
MAR 15
APRIL'15
MAY'15
Month
JUNE 15
Jul-15
Aug-15
Sep-15
7.0 Standardization and control method
Item
Standard ization
Education
Horizontal
deployment
Spot shifted to
15mm
Change in
supplier part
SUDEESH/RA
JENDRAN
JUNE15
SUBFLOOR
SPOT Shift in
LOWER ASSY REAR
CROSS PART AT
GSSA supplier
TPM check
point .
SUDEESH
JUNE 15
SUBFLOOR
STUD Weld
Operation
standards
RAJAGOPAL
MAY15
SUBFLOOR
Operator
training and
Awarness
To improve knowledge
on stud weld failure
modes
SUDEESH/RA
JAGOPAL
MAY 15
SUBFLOOR
Practical genba
Training on stud
weld failure modes
with Tear down
confirmation
FRONT
FLOOR
SUDEESH
JUNE15
SUBFLOOR
VASU- Importance of Team Work by Brain Storming will result in Effective Countermeasures.
KARTHICK - We Understood the importance of PDCA which is very important for permanent
solution to Problems
RAMUKUMAR- GOOD TEAM ACTIVITY ,MANY IDEAS GENERATE FROM TEAM
PERYIA We Learnt the importance of Cause and Effect Diagram and the usage of QC tools.
Body shop
Thank you very much for attention