This presentation is glimpse of how i did a Six Sigma activity in my Green Belt Project, I lead a project to control machining to machining variation in a product for JCB INDIA LTD.

1. Process Improvement
Before After
Positional NG issues in Flywheel Housing JCB Process improvement suggestion has been
discussed in CFT and approved,
implementation.
This improvement is done against the Problematic issue in JCB from the development of the component in ACE-3.

2. Cross Functional Team
For all the non-conforming issues in JCB, CFT was formed and Brain
Storming was done, and all the results and probable causes were
validated, and actions were planned and executed.
Sl.No
. Name Function Role Responsibility Concern
1
MR. HITESH
BHANOT
OPERATIO
NS LEADER Monitoring of the Task Resource Availability
2
Ankur
Sharma Quality Monitor
Inspection &
Monitoring Daily Monitoring
3
Shripal
Chaudhary Production Production
Production and
Consistency
Production and
Consistency
4
Vijay
Prakash
Maintenanc
e
Maintenanc
e
Maintenance & Health
of Machinery
Repair of Machines
and Fixtures

3. Probable Causes and Validation
Defect : Position of Bores J & K.
Sr. No. Potential Cause Testing Method Validation Result Significant
1 Machining to machining variation. GEMBA VALID Significant
2 Tool loose clamping in fixture MACHINE
VALID
Significant
3
Hydraulic pressure sustenance
during operation, accumulator’s
gas leakage.
GEMBA VALID Significant
4
Machining path of tools and their
circular interpolation.
GEMBA VALID Significant

4. Probable Causes and Validation
Sr. No. Potential Cause
Testing
Method
Validation Concern Validation Observation
1
Machining
to
machining
variation.
GEMBA
Specification being maintained
machining to machining, so
variation in any aspect may lead to
NG observation.
Variation is there as loading of
component is manual in practice,
against reference dowels.
2
Tool loose
clamping in
fixture
MACHINE
Tool loose issue observed as draw
bar’s disc springs observed plain
during analysis.
Disc Springs of HMC has been
replaced and horizontal deployment
plan is under process.
3
Hydraulic
pressure
sustenance
during
operation,
accumulator
gas leakage.
GEMBA
Accumulator’s pressure is
suspected as no any method for
inspecting pressure was there.
Accumulator’s has been charged and
affixed
4
Machining
sequence of
heavy and
light tools
GEMBA
Heavy tools operating after light
tools may disturb the component.
Heavy tools and light tools sequence
was not optimum.
Defect : Position of Bores J & K.

5. Action Plan
Sr. No. Potential Cause
Testing
Method
Analyzed Cause Action Plan
1
Machining to
machining
variation.
GEMBA
Variation is there as loading od
component is manual in
practice, against reference
dowels.
-
2
Tool loose
clamping in
Spindle
MACHINE
Tool loose issue observed as
draw bar’s disc springs
observed plain during
analysis.
Disc Springs of HMC has been replaced
and horizontal deployment plan is under
process (to be completed by 15-01-
2021).
3
Hydraulic
pressure
sustenance
during
operation,
accumulator
gas discharged.
GEMBA
Accumulator’s pressure is
suspected as no any method
for inspecting pressure was
there.
Accumulator’s has been charged and
affixed
4
Machining
sequence of
heavy and light
tools
GEMBA
Heavy tools and light tools
sequence was not optimum.
Heavy tools are being machined prior to
light tools.
Defect : Position of Bores J & K.

6. Action Plan
Defect : Position of Bore J.

7. Action Plan
Defect : Position of Bore K.

8. Action Plan
Defect : Position of Bore J & K.
Holes B and C are being
used to machine OP 20 as
reference dowels, variation in
machining is because of the
interference in Fixture Pins
and Dowel ID’s.

9. Action Plan
Defect : Position of Bore J & K.
Holes B and C are being
used to machine OP 20 as
reference dowels, variation in
machining is because of the
interference in Fixture Pins
and Dowel ID’s.

10. Action Plan
Defect : Position of Bore J & K.
Holes B and C are being
used to machine OP 20 as
reference dowels, variation in
machining is because of the
interference in Fixture Pins
and Dowel ID’s.

11. Action Plan
Defect : Position of Bore J & K.
Holes B and C are being used to machine OP 20 as reference dowels, variation in machining is because of
the interference in Fixture Pins and Dowel ID’s, Hole J and K are being machined with respect to these dowel
holes.
We have now analysed and found feasibility of taking another reference for machining instead of DATUM
hole B.

12. Action Plan
Defect : Position of Bore J & K.
We will now take C and C2 as
machining reference and will
machine Datum hole B in OP 20
along with J and K Holes, CD of
Dowels will also be maintained in
OP 20 along with J and K Holes.

13. Action Plan
Defect : Position of Bore J & K.
We will now take C and C2 as
machining reference and will
machine Datum hole B in OP 20
along with J and K Holes, CD of
Dowels will also be maintained in
OP 20 along with J and K Holes.
Hole
J
Hole
K
C2

14. Action Plan
Defect : Position of Bore J & K.
We have created a manual fixture
for Flywheel Housing same replica
of Hydraulic fixture.

15. Action Plan
Defect : Position of Bore J & K.
We have successfully tested the
manual fixture to be précised same
as like hydraulic fixture. By
validating the fixture

16. Action Plan
Defect : Position of Bore J & K.
New Dowel pin designed as per the concept of making arbitrary dowel.

17. Action Plan
Position of Bore J & K achieved within Specifications and Samples approved by JCB