2. 2
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
QC STORY PROJECT
PROJECT TITLE :-
Elimination of Battery mounting not done
concern in Alfa Assy line
Mahindra and Mahindra Ltd, Zaheerabad Plant, Vehicle PU
Plan Actual
Start Date 08.10.12 18.10.12
Completion
Date
04.05.13
Current Status:
CLOSED
3. 3
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Phase II – QC Story
• Team Information
• Step1: Select the Theme
• Step 2: Justify the choice
• Step 3: Understand the current situation
• Step 4: Select Targets
• Step 5: Analysis (Level 1 Analysis)
• Step 6: Implement corrective measures
• Step 7: Confirm the Effects
• Step 8: Standardise
• Step 9: Summarise & Plan future actions
• Guidelines to user
4. 4
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Cross Functional Team
No Descripti
on
Name Designation Dept Phone Email
1 Team
Leader
K. Vamsi
Krishna
Graduate
Engineering
Trainee
Vehicle PU 8008491307 23040463@m
ahindra.com
2 Mentor Mr. Abburi
Purna
Asst. Manager Vehicle PU 9676197179 23075380@m
ahindra.com
3 Member 1 K Chaitanya
Kumar
Asst Manager Vehicle PU 9652262699 23066128@m
ahindra.com
4 Member 2 D Suresh Manager Vehicle PU 9949396000 205763@mah
indra.com
5 Member 3 K Chakravarthy Manager Vehicle PU 9989922011 205755@mah
indra.com
6 Member 4 Gr suresh Dy. Manager Vehicle PU 9866287959 208981@mah
indra.com
7 Member 5 Bhanu Prakash Asst Manager SQA 9393315415 23069691@m
ahindra.com
5. 5
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
1. Select the Theme
Brief description of Problem
Around of 180 veh per month are reworked in buy-off and hold rework
regarding battery mounting.
What: Battery mtg not done
Where: In Alfa (3 wheeler) Mechanical assembly Line.
When : Identified while assembling
Who : Reported by the stage operator and intermediate Buy Off
operators
Why :
How: * It got noticed during the inspection at buy off stage
* Around of Avg 180 veh per month are reworked in buy-off and
hold rework regarding battery mounting.
6. 6
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
2a. Justify the choice (reasons)
PARETO OF Battery mtg not done concerns over
PERIOD APR’12 TO Oct’12
• Vehicle loss getting reworked for battery mtg not done : F13 ( High Occurrence)
• High severity rating: 8
7. 7
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
2b. Immediate Containment Action
• Rework for Battery mtg not done will be done at IP buy-off
if rework doesn’t complete in time vehicle is reworked at
hold rework area.
9. 9
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Vehicles get reworked due to Battery mtg not done are around 180 veh /month
Total Vehicle reworked in F-13 (Apr’12 to Oct’12)= 1252 veh
3. Understand the current situation
10. 10
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
4. Select Target
Present
Level:
Target:
1689 vehicles reworked in F-13( Apr’12 to Oct’12)
Zero Vehicle loss in next months, i.e.from May’13
GOOD
11. 11
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
5. Analysis 5.1 Identify possible causes:
MACHINE
MAN
METHODMATERIAL
Battery tension rod mtg hole offset
Battery tension rod mtg brkt nut portion bur
Operator Fatigue
Bundy tube fouling to Battery
Tray mtg hole area Dent on Body
operator not followed SOP
inadequate SOP
Tension rod threads not projecting out
Tension rod thread bur/Damage
Gun malfunction
Sealant excess on Battery mtg area
SOP not there
L Bracket bend/ Position Shift
L Bracket miss
Driver seat rod fouling to battery
New operator
Battery tray wrong part
Tray mtg side brkts bend/ Position shift
Battery brkt mtg nut slip
L brkt hole miss
Tension rod mtg hole miss on body
Tray mtg hole miss
Tray mtg bottom extended part to enter body hole operation miss
Tray crack
Tension rod mtg battery brkt hole miss
Tension rod mtg battery brkt hole offset
FRL malfunctioning
SOP key point miss
Tool worn out
Wrong socket used
Wrong nylock nut used
Operator skill
Battery tension rod adjustment not done
Battery NSP on tray
Tray wrong part
Wrong tension rod used for different models
Battery mtg area uneven/major dent
Battery wrong position placed
Wrong battery usage for different models
Battery tension rod mtg brkt bend/twist
Tension rod mtg battery brkt hole undersize
No correct process is defined
Wrong process used in achieving
Battery tension rod mtg brkt nut mtg brkt bend/damage
Battery mtg
not done
12. 12
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
5. Analysis
S. No Probable Cause
1 Operator Fatigue
2 L Bracket bend/ Position Shift
3 Tension rod mtg battery brkt hole undersize
4 Tension rod threads not projecting out
5 Bundy tube fouling to Battery
6 Battery tension rod mtg brkt bend/twist
7 Sealant excess on Battery mtg area
8 Tray mtg side brkts bend/ Position shift
Probable Causes: (Based on experience & Knowledge)
Eight Probable causes selected out of 44 possible causes for testing i.e.
establishing root causes.
13. 13
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
1
Operator Fatigue
Operator has to take the battery(Wt:15kg’s)
from the pallet at certain height and place it
on the vehicle as the bending and weight
Holding to 140 veh daily leading to fatigue.
Hypotheses
valid
5.2 Confirm the probable cause:
5. Analysis
14. 14
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
2
L bracket
Bend/Position
shift
The L brkt position is getting shifted at the
supplier end while L brkt placed in fixture its
position is getting shifted while welding the
bracket to the body, which in turn leads to the
Tension rod threads not projecting outside the
battery mtg bracket hole.
Hypotheses
valid
5.2 Confirm the probable cause:
5. Analysis
15. 15
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
3
Tension rod
mtg battery brkt
hole undersize
In mounting the Battery bracket , tension rod
may not enter the battery brkt, as its hole is
undersize leading the battery mtg not done
Hypotheses
Invalid
5.2 Confirm the probable cause:
5. Analysis
16. 16
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
4
Tension rod
threads not
projecting out
Dimension of the tension rod mtg adjuster rod
and plain rod variation leading to tension rod
threads not projecting out, leading to Battery mtg
not done
Hypotheses
Invalid
5.2 Confirm the probable cause:
5. Analysis
17. 17
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
5
Bundy tube
fouling to
Battery
Bundy tubes which is mounted to TMC, in that T-
joint mtg bundy tube coming out of the guided
side brkts and obstructs the Battery mtg.
Hypotheses
valid
5.2 Confirm the probable cause:
5. Analysis
Improper bending profile of the
Bundy tube projecting out of the
tray stopper and fouling to battery
leading to battery mtg not done
Improper bending profile of the
Bundy tube projecting out of the
tray stopper and fouling to battery
leading to battery mtg not done
18. 18
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
6
Battery tension
rod mtg brkt
bend/twist
Battery tension rod mtg Brkt if twisted leads to
mtg hole offset and battery mtg not done.
Hypotheses
Invalid
5.2 Confirm the probable cause:
5. Analysis
19. 19
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
7
Sealant excess
on Battery mtg
area
Excess sealant application at the Battery tray
mtg area leads to Battery tray NSP, and battery
mtg not done.
Hypotheses
valid
5.2 Confirm the probable cause:
5. Analysis
Unwanted sealant at the battery tray
mtg area leads to tray NSP into its
mtg hole and leading to Battery mtg
not done hence Hypothesis valid
Unwanted sealant at the battery tray
mtg area leads to tray NSP into its
mtg hole and leading to Battery mtg
not done hence Hypothesis valid
20. 20
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
No Probable Cause Testing and Observations Conclusion
8
Tray mtg side
brkts bend/
Position shift
Battery Tray mtg brackets position shifted leads
to Tray not seated properly and bundy tubes
projects outside leading to Battery mtg not
done
Hypotheses
valid
5.2 Confirm the probable cause:
5. Analysis
21. 21
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
5. Analysis
S. No Probable Cause Remarks
1 Operator Fatigue Hypotheses valid
2 L Bracket bend/ Position Shift Hypotheses valid
3 Bundy tube fouling to Battery Hypotheses valid
4 Sealant excess on Battery mtg area Hypotheses valid
5 Tray mtg side brkts bend/ Position shift Hypotheses valid
Following are the Probable causes identified for the conveyor breakdowns
5.2 Confirm the probable cause:
22. 22
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
WHY - WHY Analysis
S. No Valid Probable
Cause
WHY WHY WHY
1 Operator Fatigue
Operator has to bend
and lift the Battery
from the pallet(15 kg’s
weight)
Because there is no
alternative mechanism, he
places manually
Due to the design
limitations of the
working area
2 L Bracket bend/
Position Shift
Position shifted while
welding the brkt to the
Body
While welding the Brkts to
the body in fixture, twisting
of brkt occurs
Due to the fixture
limitations while
welding Brkts
5.3 Identify the root causes:
23. 23
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
WHY - WHY Analysis
5.3 Identify the root causes:
S. No Valid Probable
Cause
WHY WHY WHY
4 Bundy tube fouling
to Battery
Bundy tube projecting
out of the side brkts
and fouling to battery
In design the bending angle
and degrees not specified
only supplier supplying
based on master sample.
Master sample
variation at supplier
end
5 Sealant excess on
Battery mtg area
Sealant provided on
the Body as surface at
that Tray area as the
area is uneven
As the part is welded on the
body for supporting
Due to the design
6 Tray mtg side brkts
bend/ Position shift
Position shifted while
welding the brkt to the
Body
While welding the Brkts to
the body in fixture, twisting
of brkt occurs
Due to the fixture
limitations while
welding Brkts
24. 24
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
6. Implement the corrective measures
6.1 Actions Decided
Root Cause Action Plan Target
Dt
Resp. Status
Operator
Fatigue
Operator fatigue can be
eliminated completely by
providing the pneumatic
fixture for lifting the battery.
10.01.13
GR suresh/
K. Chaitanya
Closed
L Bracket bend/
Position Shift
The bracket shifting is
completely eliminated by
providing the magnetic
surface area over the fixture,
which eliminates the brkt
position shifting/bend
13.01.13 Sarapu Bhanu
Closed
25. 25
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
6. Implement the corrective measures
6.1 Actions Decided
Root Cause Action Plan Target
Dt
Resp. Status
Bundy tube fouling
to Battery
Raised the DCR and corrected
the bending profile from 49.52 to
38.87 for avoiding the Bundy tube
to contact with tray and Battery
15.04.13 K.vamsi/VGS EN under
progress
Sealant excess on
Battery mtg area
Permanently delete the sealant
application at battery tray mtg
area
10.09.12
Manikappa/
YSN Murthy
Closed
Tray mtg side brkts
bend/ Position shift
The bracket shifting is completely
eliminated by providing the
magnetic surface area over the
fixture, which eliminates the brkt
position shifting/bend
13.01.13 Sarapu Bhanu Closed
26. 26
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Root Cause Action Plan Target Dt Resp. Status
Operator Fatigue
Operator fatigue can be
eliminated completely by
providing the pneumatic fixture
for lifting the battery.
10.01.13
GR suresh/
K. Chaitanya
Close
d
6. Implement the corrective measures
By providing the Pneumatic fixture
the operator stress in lifting the
battery and placing on vehicle is
completely eliminated
By providing the Pneumatic fixture
the operator stress in lifting the
battery and placing on vehicle is
completely eliminated
27. 27
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Root Cause Action Plan Target
Dt
Resp. Status
L Bracket bend/
Position Shift
The bracket shifting is
completely eliminated by
providing the magnetic surface
area over the fixture, which
eliminates the brkt position
shifting/bend
13.01.13 Sarapu Bhanu Closed
6. Implement the corrective measures
The bracket shifting is
completely eliminated by
providing the powerful
magnet which prevents
the brkt shift/Bend during
welding to body
The bracket shifting is
completely eliminated by
providing the powerful
magnet which prevents
the brkt shift/Bend during
welding to body
28. 28
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Root Cause Action Plan Target Dt Resp. Status
Bundy tube fouling to
Battery
Raised the DCR and corrected
the bending profile from 49.52
to 38.87 for avoiding the Bundy
tube to contact with tray and
Battery
15.04.13 K.vamsi/VGS EN under
progress
6. Implement the corrective measures
Bundy tube fouling to Tray eliminated by
correcting the bending profile
Bundy tube fouling to Tray
causing to tray crack
30. 30
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Root Cause Action Plan Target Dt Resp. Status
Sealant excess
on Battery mtg
area
Permanently delete the sealant
application at battery tray mtg area 10.09.12
Manikappa/
YSN Murthy
Closed
6. Implement the corrective measures
In order to eliminate the issue of battery tray not fitted in Alfa Model due to sealer bead obstruction
We have taken the below action
Concern: Battery tray Not Fitted due to excess Sealer
PCA: Sealer cutting at Battery Tray Bracket
Cut off No: From 10.09.2012 Second shift
vehicles
6536-478 ( Alfa Pass ) & 6536-244 ( Alfa LC)
31. 31
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Root Cause Action Plan Target Dt Resp. Status
Tray mtg side
brkts bend/
Position shift
The bracket shifting is completely
eliminated by providing the
magnetic surface area over the
fixture, which eliminates the brkt
position shifting/bend
13.01.13 Sarapu Bhanu Closed
6. Implement the corrective measures
The side bracket shifting
is completely eliminated
by providing the powerful
magnet which prevents
the brkt shift/Bend during
welding to body
The side bracket shifting
is completely eliminated
by providing the powerful
magnet which prevents
the brkt shift/Bend during
welding to body
32. 32
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
7. Check & confirm the results & effects
7.1 Verify Results:
7.2 Full Scale Implementation plan:
Root Cause Action Plan Target Dt Resp. Status
Bundy tube fouling to
Battery
Raised the DCR and corrected the bending
profile from 49.52 to 38.87 for avoiding the
Bundy tube to contact with tray and Battery
15.04.13 K.vamsi/VGS Closed
Sealant excess on Battery
mtg area
Permanently delete the sealant application
at battery tray mtg area 10.09.12
Manikappa/
YSN Murthy
Closed
Tray mtg side brkts bend/
Position shift
The bracket shifting is completely
eliminated by providing the magnetic
surface area over the fixture, which
eliminates the brkt position shifting/bend 13.01.13 Sarapu Bhanu Closed
After Implementing corrective actions, like tray mtg area sealant deletion, Bundy tube profile
correction and gauge correction at supplier end completely resolved the issue.
33. 33
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
7.3 Tangible Benefits
1.Elimination of V1 Concern
2. Improvement in quality indicators (FRC, FBO & DPV)
3. Rework cost saved (Avg 180veh/month-Rs. 38,880/- per year)
4.Rework at hold eliminated.
5.Customer quality increases
6. Improved Delivery performance in PDI
7.3 Intangible Benefits
Morale of the operator is increased.
Customer satisfaction increases
7. Check & confirm the results & effects
34. 34
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
8. Standardisation
8.1 Updation of documents:
8.2 Training:
8.3 Additional Audit / Check
DCP documents PFC,PFMEA, CP & SOP updated.
Drawings updated.
Process sheets updated.
Concerned operators are made familiar with the system regarding its
function, operation
FTG Audit
35. 35
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
9. Summarise & Plan future actions
9.2 Horizontal Deployment:
9.3 Lessons Learnt:
9.1 Conclusion:
By doing the several analysis, concluding the results from analysis the top
FBO effecting concern is thrown out completely.
TGR: Implementing corrective actions, like tray mtg area sealant deletion,
Bundy tube profile correction and gauge correction at supplier end completely
resolved the issue.
TGW: Nil
Horizontal deployment can be applied for all 3-wheeler model manufacturers.
Information shared with HARIDWAR also.
