Elimination of Wastages was key to achieve the Through Put Yield, for that among 8 losses of lean i choose Over processing as my area of concern and CAPA.

1. Project Theme : To Improve Through Put Yield of the Plant.
Sponsor / Champion : Mr. SHAKTI SINGH
Black Belt : Mr. SHAKTI SINGH
Team Leader : ANKUR SHARMA
LEAN SIX SIGMA – PROJECT REPORT

2. INTRODUCTION
Brief description of unit: AMTEK AUTO LIMITED SHED-3
We carry out the machining (Milling, Boring, Drilling, Tapping and
Grooving Operations) on the Grey Cast Iron Castings.
All of our customers are OEM’s and we are tier 1 supplier to JCB INDIA
LIMITED, Case New Holland Private Limited, John deere INDIA Pvt.
Limited, Swaraj Mazda ISUZU Limited, Ashok Leyland Limited, Eaton
INDIA Pvt. Limited.

3. AMTEK AUTO LIMITED SHED-3
PLANT & FACILITY

4.  JCB INDIA LIMITED
 NEW HOLLAND INDIA LIMITED
 SML ISUZU LIMITED
 EATON
OUR ESTEEMED CUSTOMERS

5. CUSTOMER PORTFOLIO
P.T.O. F.A.S.
Cylinder
Head
F.A.S.
Case
Transmission
Case
Transmission
King Post Flywheel Housing Gear Case Drive Head Axle Arm
Cylinder
Block

6. JCB - Drive Head JCB - FLYWHEEL HOUSING CNH - FAS PTO CONVERTOR
OUR PRODUCTS
JCB - KING POST JCB - GEAR CASE SML -CYLINDER BLOCK EATON - Transmission case

7.  Introduction
 Definition of Project
– Project title, Target, Business Case, Team, SIPOC, Process Map.
 Measure
– Trends, CTQ, Check sheet, data collection
– Cause & Effect Diagrams, Potential causes
 Analyse
– Physical Mechanism (PM) Analysis, Potential Xs, Verification of Xs,
– Identify root cause & validate, % contribution of each cause, Design of Experiments
– Quick hit action points
 Improve
– Implement identified actions, Improvements in X, Verification of Results
 Control
– Control Plan, SPL, SOP, Training
 Financial Benefits
REPORT STRUCTURE

8. DMAIC
D E F I N E
 Definition of Project
– Project title
– Target
– Business Case
– Team
– SIPOC
– Process Map
DEFINITION

9. DMAIC
Project Title
Title of the Project is to improve Through Put Yield by using basic tools
of Lean(Waste Elimination) Six Sigma(Control Over Variations).

10. DMAIC
Target and Business Case
Direct & Tangible Target of Savings – INR Three-Four Lacs PER ANNUM
Indirect & Intangible Target – Lead Time of Conversion of RM into FG
will be Reduced.
Business Case – Business will be in direct impact as if FTY is improved
time bound feeding to Customer’s line will be achieved.

11. DMAIC
Name Function Key responsibilities
Mr. SHAKTI SINGH OPERATIONS Member in G shift
Mr. VINOD KR. VERMA PRODUCTION Member in G shift
Mr. MANOJ KR. SHARMA QA Member in G shift
Mr. SHRIPAL TOOLING Member in G shift
Mr. HANSRAJ QA Member in G shift
Mr. Kalamuddin/Mr. SUNIL DUTT QA G shift (FROM FOUNDRY)
Team Members

12. General Process Flow Diagram (SIPOC)
Supplier
CASTEX/JCB/SML
Oiling
&
Packing
Castings
Input Process Output Customer
Machining
(Finish
Milling,
Drilling,
Tapping,
and Boring)
Finished
Goods
JCB/SML/CNH
EATON
DMAIC

13. Process Mapping/Road Map
1. Identification of type of Losses in our facility & Components.
2. Discrimination of losses into Lean and Six Sigma.
3. Selection of Tool.
4. Application of Tool.
5. Results after application.
6. Monitoring of Results and Savings Calculation.
DMAIC

14. DMAIC
MEASURE
 Measurement
– Strategy of work
– Listing Issues and Impact.
– Targets.
– Cause & Effect Diagrams.
– Listing of Probable Causes.
Measurement

15. Measurement
8 Losses of Lean: Six Sigma:
T – Transport – Constraint. Control Over Variations
I – Inventory – As per Customer & Norms.
M – Motion – Constraint.
W – Waiting – As per Machine availability
& Volumes.
O – Over Production – As per Customer & Norms.
O – Over Processing
D - Defect
S - Skill
Strategy how Team will work upon
Stage - 1 Stage - 2
DMAIC

16. Listing of Issues and Impact
Customer Component Issue w.r.t. Through Put Yield Impact
JCB Flywheel
Housing
1. Finn in Window area after machining
OP 10. Grinding being done.
2. Wall Shifting after OP 10, grinding
required on wall adjacent to tapping
Hole M50X2. Grinding being done.
1. Over Processing Loss : As
Components after machining gets
hold for grinding.
2. As grinding is done manually, so lead
time at this process is variable and
skill bound.
JCB Gear Case
VAVE
Machining mold hole Ø83 mm.
1. Over Processing loss : As this machining
is not required in Drawing, additional
machining is being done. Cycle time of
machining is raised because of this.
JCB Drive Head
3DX/3CX
Chamfer less over Ø88
Grinding being done.
1. Over Processing Loss : As
Components after machining gets
hold for grinding.
2. As grinding is done manually, so lead
time at this process is variable and
skill bound.
DMAIC

17. Listing of Issues and Impact
Customer Component Issue w.r.t. Through Put Yield Impact
JCB King Post 1. Grinding requires after machining.
1. Over Processing Loss : As
Components after machining gets
hold for grinding.
2. As grinding is done manually, so lead
time at this process is variable and
skill bound.
3. Electric Grinder and Wheels as
consumables.
4. Additional Manpower requires.
5. Grinding dust spoils HMC’s.
DMAIC

18. Listing of Issues and Impact
Customer Component Issue w.r.t. Through Put Yield Impact
JCB Axle Arm Punching of Traceability on components
after machining.
1. Manual punching is being done and
components got on hold after
machining
2. As Punching is done manually, so
lead time at this process is variable
and skill bound.
3. Additional manpower requires.
SML Block Cylinder
1. Additional machining being done at
specific sections to assist assembly line at
SML.
1. Over Processing losses on HMC.
DMAIC

19. DMAIC
Trends of the Issues
Flywheel Housing
Issue 1 – Finn in window area after OP 10
100%100%100%100%100%100%100%100%100%
35%
0 0 0 0 0 0 0 0 0 0
0%
50%
100%
150%
Percentage of Loss
Percentage of Loss
Issue 2 – Casting Shifting against locator
30 27
38 36 38 34 34 37 38 38 42 39 41 43 44
37
0
39
49
14
0
20
40
60
Percentage of Loss
Percentage of Loss

20. DMAIC
Trends of the Issues
Gear Case Issue – Machining mold hole Ø83 mm.
100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%
57%
0
0%
50%
100%
150%
Percentage of Loss
Percentage of Loss
Issue – Ø88 Chamfer less due to casting issue
16% 16% 15% 15% 15%
9% 9% 8%
6% 6% 5% 4%
6% 5% 5% 4% 5%
19%
15%
0%
5%
10%
15%
20%
Percentage of Loss
Percentage of Loss
Drive Head 3DX/3CX

21. DMAIC
Trends of the Issues
King Post Issue – Grinding after machining
100%100%100%100%100%100%100%100%
50% 50% 50% 50% 50% 50% 50% 50% 50% 50% 50% 50%
0%
50%
100%
150%
Percentage of Loss
Percentage of Loss
Issue – Excess machining to assist assembly at SMLI
100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%
0%
50%
100%
150%
Percentage of Loss
Percentage of Loss
SML – Block Cylinder

22. BRAIN STORMING
WHEN
WHERE
WHY
WHAT
HOW
DMAIC

23. PROBABLE CAUSES
Customer Component Non Conformance Probable Causes Validation Result
JCB Flywheel
Housing
1. Finn in Window
area after
machining OP 10.
Grinding being
done.
2. Wall Shifting after
OP 10, grinding
required on wall
adjacent to
tapping Hole
M50X2. Grinding
being done.
Loose Core Not Valid
Pattern Broken Not Valid
Low Sand mold Hardness Not Valid
NO Relief in tooling Valid
Extra Casting Valid
Locator NG Valid
Air Went not OK Not Valid
DMAIC

24. PROBABLE CAUSES
Customer Component Non Conformance Probable Causes Validation Result
JCB Gear Case
Machining mold hole
Ø83 mm.
Loose Core Not Valid
Pattern Broken Not Valid
Low Sand mold Hardness Not Valid
NO Relief in tooling Valid
Extra Casting Valid
Locator NG Valid
Air Went not OK Not Valid
DMAIC

25. PROBABLE CAUSES
Customer Component Non Conformance Probable Causes Validation Result
JCB Drive Head
Chamfer less over Ø88
Grinding being done.
Loose Core Not Valid
Pattern Broken Not Valid
Low Sand mold Hardness Not Valid
NO Relief in tooling Valid
Extra Casting Valid
Locator NG Valid
Air Went not OK Not Valid
DMAIC

26. PROBABLE CAUSES
Customer Component Non Conformance Probable causes
JCB King Post 1. Grinding requires
after machining.
1. Legacy issue.
2. Burr is BI-Product of machining.
JCB Axle Arm
Punching of
Traceability on
components after
machining.
N/A
SML Block Cylinder
1. Additional
machining being done
at specific sections to
assist assembly line at
SML.
N/A
DMAIC

27. DMAIC
ANALYZE
 Analysis
– WHY-WHY ANALYSIS
– Validation of Causes
ANALYZE

28. DMAIC
WHY-1
Finn
Observed
after
machining
WHY-2
Mold box
is being
unboxed
and fin is
broken
with chisel
and
Hammer
Custo
mer
Compon
ent
Non
Conformance
Probable
Causes
Validation Result Constraint
JCB Flywheel
Housing
1. Finn in
Window
area after
machining
OP 10.
Grinding
being done.
Finn of Mold Box Valid Section is being unlocked after
mold setting, and being broken
with chisel and hammer, zero finn
is not feasible and grinding finn
before machining will lead to
crack issues in transit.
WHY-3
No relief is
there in
core
WHY-4
Castings on
lower limit
of tolerance
and no
permissible
degree of
draft
ANALYZE

29. DMAIC
WHY-1
Locator
tolerance
with mold
cavity is in
range of 1.6
mm.
WHY-2
Shifting
observes
on
opposite
side of the
locator.
Custo
mer
Compon
ent
Non Conformance Probable
Causes
Validation
Result
Constraint
JCB Flywheel
Housing
1. Wall Shifting after OP 10,
grinding required on wall
adjacent to tapping Hole
M50X2. Grinding being
done.
Locator
Tolerance
Valid Locator range of 1.6 mm and
mismatch allowed of 1 mm in
drag and cope as per
standard ISO 8032 C09 JCB.
WHY-3
No relief
has been
extended
as against
the locator
variation.
WHY-4
Castings on
lower limit
of tolerance
and no
permissible
degree of
draft
WHY-5
ANALYZE

30. DMAIC
WHY-1
Finn has to
be removed
at
machining
WHY-2
Finn
relaxes as
is in Drag
Side of
pattern
WHY-3
No Sand in
Casting
process
WHY-4
Tooling
constraint
Customer Component Non Conformance Probable Causes Validation Result
JCB Gear Case Machining mold hole
Ø83 mm.
NO Relief in tooling Valid
Section with finn in mold hole
is in Drag pattern of the
casting.
ANALYZE

31. DMAIC
WHY-1
Secondary
Core
shifting
issue in
castings
WHY-2
Core tilted
due to more
interference
and manual
application
WHY-3
Sand mold
making
tool die
worn out
WHY-4
Life of
Tooling has
been
achieved
Custo
mer
Compon
ent
Non
Conformance
Probable Causes Validation Result Constraint
JCB Drive
Head
Chamfer less over
Ø88
Grinding being
done.
Excess Relief in tooling Valid
Tooling life has been
achieved.
ANALYZE

32. DMAIC
Customer Component Non Conformance Probable causes
JCB King Post 1. Grinding requires
after machining.
1. Legacy issue.
2. Burr is BI-Product of machining.
JCB Axle Arm
Punching of
Traceability on
components after
machining.
N/A
SML Block Cylinder
1. Additional
machining being done
at specific sections to
assist assembly line at
SML.
N/A
ANALYZE

33. DMAIC
IMPROVE
 Action Plans and Executions
IMPROVE

34. DMAIC
IMPROVE
Customer Component Non Conformance Root Causes Action Plan/Executed
JCB Flywheel
Housing
1. Finn in Window
area after
machining OP 10.
Grinding being
done.
Castings on lower
limit of tolerance
and no
permissible
degree of draft.
Casting of 1.5 mm at a permissible draft
of 3 degree as per ISO 8032 C09 Standard,
that will ensure, after machining from
Drag to cope side during machining finn
will chipped off.
Only Filing is enough to remove these
sharp edges
Improved Castings

35. DMAIC
IMPROVE
Customer Component Non Conformance Root Causes Action Plan/Executed
JCB Flywheel
Housing
1. Wall Shifting after
OP 10, grinding
required on wall
adjacent to
tapping Hole
M50X2. Grinding
being done.
Castings on lower
limit of tolerance
and no permissible
degree of draft
A linear relief of 0.7 mm has been given
in castings by grinding pattern at tooling
to compensate the variation due to
Locator pad.
Castings will be received un batches of
14.7-15.5 mm.
15.6-16.3 mm.

36. DMAIC
IMPROVE
Customer Component Non Conformance Root Causes Action Plan/Executed
JCB
Gear Case
1. Machining mold
hole Ø83 mm.
Tolling Constraint
to avoid finn from
this hole.
Upon mutual discussion with JCB, it has
been finalized that his finn won’t be an
trouble at JCB assembly as far as there is
no sharp edge in ID.

37. DMAIC
IMPROVE
Customer Component Non Conformance Root Causes Action Plan/Executed
JCB Drive Head Chamfer less over Ø88
Grinding being done.
Excess Relief in tooling, Life of
Tooling has been achieved
Two slips has been added at
secondary core placement so
that no relief is left for core
tilting.
New Tooling From JCB has
reached CASTEX and is under
verification

38. DMAIC
IMPROVE
Customer Component Non Conformance Root Causes Action Plan/Executed
JCB King Post Grinding requires after
machining.
Legacy Issues and Burr being
the BI-product of the process
From Section one, Y travel of
cutter has been made -1 mm,
and grinding has been
stopped.
Instead of Electric grinder,
Pneumatic grinder with steel
tool has been introduced.
Section-1 Section-2

39. DMAIC
IMPROVE
Customer Component Non Conformance Root Causes Action Plan/Executed
JCB Axle Arm Punching of Traceability
on components after
machining.
N/A
Instead of Punching, itching has been
proposed on component at different
locations and is under approval phase
from JCB.

40. At these specific locations, 100% machining is being done to assist assembly at SML.
1.
2.
IMPROVE
DMAIC

41. At this specific location, 100% machining is being done to assist assembly at SML.
3.
IMPROVE
DMAIC

42. At this specific location, 100% machining is being done to remove unwanted finn from the
cross section to assist assembly at SML.
4.
IMPROVE
DMAIC

43. DMAIC
CONTROL
 CONTROL
– Controls has been placed and standardization is being Done.
CONTROL

44. BENIFITS
 BENIFITS
– Tangible and Intangible benefits are under calculation.
BENIFITS

45.  SKILL : Volunteer Training Program AMTEK AUTO LIMITED SHED-3
SKILL

46. STAGE-2 – SIX SIGMA
To be Continued ..

47. Best Regards .. Thanksgivings