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Six Sigma Project Final

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Six Sigma Project Final

  1. 1. Q-Star Advance Project 1© Copyright, Confidential, Tata Motors Ltd Lean Six Sigma ProjectLean Six Sigma Project onon To eliminate sub frame mtg. holeTo eliminate sub frame mtg. hole mismatch with frame nut in TCFmismatch with frame nut in TCF Submitted by Pradeep Tiwari Ticket No. 602551 Deptt. Biw – 1C Program /Module SIX SIGMA
  2. 2. Q-Star Advance Project 4© Copyright, Confidential, Tata Motors Ltd Project Selection Check ListProject Selection Check List No. Criteria Yes No 1 Project is a strategic priority, aligned with a Big Y √ 2 There is no overlap with other GB / BB projects √ 3 Scope of the project is under the area of my influence √ 4 Project scope is limited to only one product / one type of defect √ 5 It is related to repetitive problem (chronic, not sporadic) √ 6 Team cannot solve it by engineering judgment. √ 7 A significant ROI expectation has been established √ 8 Right vertical & horizontal team members are available √ 9 Several team members are top talent & innovative thinkers √ 10 Management is willing to commit serious resources to solutions √ 11 Project is capable of completion within 2~4 months √ 12 Capable team leader and champion assigned √
  3. 3. Q-Star Advance Project 5© Copyright, Confidential, Tata Motors Ltd Business Case / Justification for Project Selection Opportunity Statement The project supports DRR & DRL improvement, COPQ Reduction and line stoppage reduction of TCF Shop. Pain : Product is getting reworked at TCF and extra 2 manpower deployed it’s repairing. Majorly produced vehicle are having same defect. Quantification : DPV of product is 3.5 & Daily 2 manpower are required for reworking this particular defect. Impact of pain in Rs. (or soft) : Rs.20.9 lack p.a. is paid for this rework. Goal statement Project scope Metric Current level Target The scope of the project begins at the time of cab being received at TCF from Paint Shop until the vehicle is fully assembled and made ready for dispatch. Sub frame rework in Super Ace / Venture 70-75% rework Zero Rework DPV- 3.5 DPV-1.0 Project plan Team Phase Start End Role Name Dept. Sponsor Mr. S. Waghchaure BIW – 1C Define 01/09/14 12/10/14 Champion / Guide Mr. Mohanish Q O Measure 13/10/14 24/10/14 Leader Pradeep Tiwari BIW – 1C Analyze 02/11/14 29/11/14 Member Ganga Singh BIW – 1C Improve 30/11/14 31/12/14 Member Vikrant TCF – 1C Control 01/01/15 30/01/15 Member Pankaj Adhikari BIW – 1C Member Ritesh Chattoo SQIG Project CharterProject Charter
  4. 4. Q-Star Advance Project 6© Copyright, Confidential, Tata Motors Ltd •The issue of Sub frame rework in DRR TCF 1C was taken up as Six Sigma project and the reason is evident from the above table. Since there are multiple and complex causes with no proper solution, I have, with the support of the management, decided to use DMAIC approach to solve the problem. Why Sub frame fitment problem as a Six sigma project?
  5. 5. Q-Star Advance Project 7© Copyright, Confidential, Tata Motors Ltd DEFINE What is the pain?
  6. 6. Q-Star Advance Project 8© Copyright, Confidential, Tata Motors Ltd DEFINE PHASE Problem Identification & JustificationProblem Identification & Justification (KPM Tree – Business Goal)(KPM Tree – Business Goal) PLANT QUALITY PERFORMANCE IMPROVEMENTPLANT QUALITY PERFORMANCE IMPROVEMENTPLANT QUALITY PERFORMANCE IMPROVEMENTPLANT QUALITY PERFORMANCE IMPROVEMENT CPACPA IMPROVEMENTIMPROVEMENT CPACPA IMPROVEMENTIMPROVEMENT REDUCE CUSTOMERREDUCE CUSTOMER (TCF) COMPLAINS(TCF) COMPLAINS REDUCE CUSTOMERREDUCE CUSTOMER (TCF) COMPLAINS(TCF) COMPLAINS Big Y (Metric) Small y’s (Key drivers) Vital X’s DIRECT RUN LOSSDIRECT RUN LOSS IMPROVEMENTIMPROVEMENT DIRECT RUN LOSSDIRECT RUN LOSS IMPROVEMENTIMPROVEMENT DIRECT RUN RATEDIRECT RUN RATE IMPROVEMENTIMPROVEMENT DIRECT RUN RATEDIRECT RUN RATE IMPROVEMENTIMPROVEMENT SHOP QUALITY PERFORMANCE IMPROVEMENTSHOP QUALITY PERFORMANCE IMPROVEMENTSHOP QUALITY PERFORMANCE IMPROVEMENTSHOP QUALITY PERFORMANCE IMPROVEMENT Engine coverEngine cover to consoleto console gap N.G.gap N.G. Engine coverEngine cover to consoleto console gap N.G.gap N.G. DoorDoor glassglass HardHard DoorDoor glassglass HardHard L/B tail gateL/B tail gate panel foulpanel foul L/B tail gateL/B tail gate panel foulpanel foul Sub frame mtg.Sub frame mtg. hole mismatchhole mismatch Sub frame mtg.Sub frame mtg. hole mismatchhole mismatch Tail gateTail gate to sideto side panel gappanel gap N.G.N.G. Tail gateTail gate to sideto side panel gappanel gap N.G.N.G.
  7. 7. Q-Star Advance Project 9© Copyright, Confidential, Tata Motors Ltd Problem Identification & Justification(Pareto & Trend Chart)Problem Identification & Justification(Pareto & Trend Chart) DEFINE PHASE
  8. 8. Q-Star Advance Project 10© Copyright, Confidential, Tata Motors Ltd Assy. Sub frame with frame Two Center Stud (LH/ RH) used to mount the engine carrying sub frame Mounting of remaining 8 studs and 6 bolts was done after the engine stuffing process.
  9. 9. Q-Star Advance Project 11© Copyright, Confidential, Tata Motors Ltd DEFINITION OF PROBLEM Frame & Sub frame hole mismatch with jack mount stud position. Side Bkt Nut offset with Sub frame Mismatch with front stud Sub frame hole mismatch with Frame Inner BKT FRAME SUB FRAME
  10. 10. Q-Star Advance Project 12© Copyright, Confidential, Tata Motors Ltd TCF Process Engine assy. With Sub Frame. Sub frame fastener torquing. Comp. Assy sub fame from BIW Assy. Comp. frame from BIW end Assy. Engine in TCF with Sub Frame Matching of sub frame & frame in TCF
  11. 11. Q-Star Advance Project 13© Copyright, Confidential, Tata Motors Ltd Assy comp. frame S.Ace Side Mtg Bkt Front Stud Mtg Bkt Jack Mtg Bkt Centre Stud Mtg Bkt Total No. of Sub frame mtg Nuts 16 No.
  12. 12. Q-Star Advance Project 14© Copyright, Confidential, Tata Motors Ltd Finished Assy. Sub frame Rack & Pinion Mtg Bkt Side Mtg Bolt Front Stud Mtg Hole Jack Mtg Hole Rack & Pinion Mtg Bkt Side Mtg Bolt Centre Stud Mtg Hole Total No. of mtg. 10 stud + 6 Bolt
  13. 13. Q-Star Advance Project 15© Copyright, Confidential, Tata Motors Ltd Matching of Sub frame with Frame . Assy SubFrame Assy Frame
  14. 14. Q-Star Advance Project 16© Copyright, Confidential, Tata Motors Ltd CTQ & CTP Drill-DownCTQ & CTP Drill-Down Critical to Quality Critical customer requirement Customer issues Voice of customer DRL to be improved Proper tightening of Bolt & Stud as per specification Sub frame & Frame mismatch issues should be avoided. Sub frame rework issues are very high in DRL. Voice of business Business issues Critical business requirement Critical for processes High customer dissatisfaction Issues in finished vehicles to be eliminated No mismatch issues DPV 3.5 TO 1.0 Tips : 1. Voice of customer and voice of business to be prioritized to those which are related to project objective 2. Use VOB or VOC or both depending on the project objectives 3. CTQ / CTP should be in NUT form (Name of the parameter, Unit of Measure, Target value) DEFINE PHASE
  15. 15. Q-Star Advance Project 17© Copyright, Confidential, Tata Motors Ltd What What is the problem? Frame nut mismatch with Sub frame mtg hole What has the problem? (part no, Lot no, etc.) Frame What is the impact of the problem? (money, people, time, etc.) High Rework impacts on time , Less Productivity, High DRL, Low Employee Moral, High Cost & Unsafe work. Where Where is problem located on Product/Part? Frame & Sub frame Where does the problem occur in the process? TCF Under Body Line St - 6 Where was the problem observed in the process? After Engine Stuffing with frame When When was the problem first noticed? From the first day of production When has it been noticed since? Regular Basis Who Who is affected by the problem? Line operator Who first observed the problem? Line Operator To whom was the problem reported? Production / BIW How How much is the problem / impact of problem? Line stoppages in TCF How is the problem being rectified / corrected? Rework by grinding & tapping. Problem Explanation (4W-1H)Problem Explanation (4W-1H) DEFINE PHASE
  16. 16. Q-Star Advance Project 18© Copyright, Confidential, Tata Motors Ltd SIPOC DiagramSIPOC Diagram Engine Stuffing Engine Stuffing Sub-processes DEFINE PHASE Suppliers Inputs BIW Sub Frame Panse Frame Engine Shop Engine Assy TCF Engine Assy with Sub Frame Outputs Customers Finished Vehicle Final PDI Assy Sub Frame Engine Assy On Sub Frame Body on Frame Engine Stuffing
  17. 17. Q-Star Advance Project 19© Copyright, Confidential, Tata Motors Ltd Top Down ChartTop Down Chart DEFINE PHASE Step-1 Step-2 Step-3 Step-4 Assy. Sub frame Engine Assy On Sub Frame Body on Frame Engine Stuffing Bush welding Assy. Side mbr LH & RH Sub frame, Spring Coil & Lower Link loading on fixture Frame comes from Panse Body comes from U/B S.No-4 and Sub frame with engine comes. Rack & Pinion ,FRT X mbr , RR X mbr weld Rack & Pinion , sub frame bkt & Power steering bottle fitment Assy U/ B weld with frame Lift up sub frame up to frame height and sub frame hole match with frame nuts SPM drilling (bush hole enlarge) FRT axle strut fitment Side wall , roof weld with frame Qualifying stud & bolt on sub frame mtg. nuts Final inspection Engine loading & fitment on sub frame Door , L/B fitment & final inspection Torqueing done as per spec. Send to Badve for powder coating Inspection engine with sub frame Comp. BIW send to paint shop Sent to TCF Engine loading Body comes Mech. Line from Paint shop Engine with sub frame unload on dolly Body comes U/B S. No. -5 Send dolly to U/B S. N.- 5 Activities
  18. 18. Q-Star Advance Project 20© Copyright, Confidential, Tata Motors Ltd Operational Definition Sl. No. Performance Indicator (Y) Operational Definition Y1 Sub frame hole not centric with frame M10 nuts Any mismatch of sub frame hole with frame nut defect which is visible to the bare. Mismatching defect may be one or more in number in a single Body but considered to be one single defective product. Sl. No. Process / input Indicator (X) Operational Definition X1 Assy. Sub frame welding Sub frame child part welding by MAG welding. X2 Complete BIW To weld cabin with frame called BIW. X3 Engine assy. On the S.F. To assemble Engine on the sub frame. X4 Engine stuffing When Engine Assembled sub frame matching with BIW frame that’s called engine stuffing operation. X5 Torqueing Tighten nuts as per spec. Called torqueing. X6 Operator Name of the operator who matching sub frame with BIW frame. X7 X8
  19. 19. Q-Star Advance Project 21© Copyright, Confidential, Tata Motors Ltd PROCESS WALKTHROUGH (3G) Final inspection Sub frame Sub frame stage -2 Sub frame stage -1 Send to Badve for ED & paint Engine Stuffing U/B ST. N. -6 Mismatch Problem occurs here Assy. Frame comes BIW -1c from supplier Comp. BIW with frame Send to Paint shop Dropping TCF – 1C Mech. line U/B ST. N. -5 Sub frame comes TCF from Badve Engine Sub Assy.-1,2 &3 Engine loading on Sub frame St. N. -4 Engine with sub frame inspection & send to U/ B line Engine with sub frame loading on Dolly U/B ST. N. -7 U/B ST. N. -11 Torqueing U/B ST. N. – 1, 2 ,3 & 4
  20. 20. Q-Star Advance Project 22© Copyright, Confidential, Tata Motors Ltd Area What Standard says? What is Observed? Photo / Sketch Potential Quick- win opportunities TCF 1C U/B Line Stage -6 Proper matching of sub frame hole with Frame mtg. nuts Sub frame hole mismatch with frame mtg. nuts. (Sub frame mtg. hole not centric with frame nuts) 1.Sub frame mtg. hole (FRT STUD HOLE) cutting and nut tapping. 2. Frame old nut replace with new nut weld. Process Walk Through (3G)Process Walk Through (3G) DEFINE PHASE
  21. 21. Q-Star Advance Project 23© Copyright, Confidential, Tata Motors Ltd Quick-Win Selection & ImplementationQuick-Win Selection & Implementation DEFINE PHASE
  22. 22. Q-Star Advance Project 24© Copyright, Confidential, Tata Motors Ltd 24 FRA ME NO. 5949 FRA ME NO. 5950 FRAM E NO. 5951 FRAM E NO. 5952 FRA ME NO. 5953 FRAM E NO. 5954 FRAM E NO. 5955 FRAM E NO. 5956 FRAM E NO. 5957 FRA ME NO. 5958 RESULT OK NOT OK OK OK OK OK NOT OK OK OK NOT OK STUD IN A TAPPER WITH FRAME FRA ME NO. 5959 FRA ME NO. 5960 FRAM E NO. 5961 FRAM E NO. 5962 FRA ME NO. 5963 FRAM E NO. 5964 FRAM E NO. 5966 FRAM E NO. 5967 FRAM E NO. 5968 FRA ME NO. 5959 RESULT OK OK OK OK OK OK NOT OK OK OK OK Process Walk Through (3G)Process Walk Through (3G)
  23. 23. Q-Star Advance Project 25© Copyright, Confidential, Tata Motors Ltd DEFINE PHASE Area What Standard says? What is Observed? Photo / Sketch Potential Quick-win opportunities TCF U/B STUD SHOULD BE QUALIFING PERPENDICULAR. Nut welded with a taper due to no standard Welding process. Above PROJECTION WELDING STARTED IN PLACE OF MAG WELDING. BeforeBefore AfterAfter Nut weld by MAG welding Nut weld by Projection weldingStud not perpendicular Process Walk Through (3G)Process Walk Through (3G)
  24. 24. Q-Star Advance Project 26© Copyright, Confidential, Tata Motors Ltd MEASURE What is the root cause?
  25. 25. Q-Star Advance Project 27© Copyright, Confidential, Tata Motors Ltd 27 Sub frame mtg. Hole mismatch with frame in TCF Unskilled manpower Behavior Irregular operator Lack of awareness Preventive maintenance of sub frame fixture Process Sequence not ok WIS not followed Tightening sequence not ok Frame Dim. Not ok Sub frame Dim. Not okNut tapered on frame Fixture Resting block condition MachineMan Material Method CAUSE AND EFFECT DIAGRAM Environment Improper Visibility Improper Space
  26. 26. Q-Star Advance Project 28© Copyright, Confidential, Tata Motors Ltd Prioritization of CausesPrioritization of Causes Mismatch 10 1- Nut taper welded in frame 3 3 2- Sub frame dim. N.G. 9 9 3- Frame DIM. N.G> 9 9 4- Low tolerance of sub frame hole 9 9 5- Wrong vehicle resting pad 3 3 6- Preventive maintenance of fixture 3 3 7- Fixture clamp & block condition 3 0 8- Unskill manpower 0 0 9- Irregular operator 0 0 10- Lack of awareness 0 0 Effect >> Importance >> Final Score Causes Relationship Scale 0 – No Relation, 1 – Week Relation, 3 – Moderate Relation, 9 – Strong Relation MEASURE PHASE
  27. 27. Q-Star Advance Project 29© Copyright, Confidential, Tata Motors Ltd Prioritization of CausesPrioritization of Causes Mismatch 10 11- WIS not followed 3 3 14- Process sequence not followed 9 9 15- Tighting sequence not ok 0 0 16- Operator training 0 0 17- Improper visiblity 0 0 18- Improper space 0 0 Effect >> Importance >> Final Score Causes Relationship Scale 0 – No Relation, 1 – Week Relation, 3 – Moderate Relation, 9 – Strong Relation MEASURE PHASE
  28. 28. Q-Star Advance Project 30© Copyright, Confidential, Tata Motors Ltd Who will collecte the data How will the data be collected How will the data be used How will the data be displayed Instrument Type Make Srl no. Operating Range Least count Last calibrated on Next calibratio n due date Method to be used No. of parts to be taken No.of appraisers (& Name) No. of reading / part /appraiser Acceptan ce criteria Resp. Target Date Attribute 50 3 1 As per sheet Pankaj 20/11/14 1-Anand 2-Gurdeep 3-Hargovind SN. Measurement system details Measurement system analysis plan Performance measure (Ys /Xs) Operational Definition Data source and location Sampling method sample size &Freq. When will the data be collected Other data that should be collected at the same time MSA Plan Data Collection Plan MSA PLAN FOR CRITICAL DIMENSIONS AT BIW
  29. 29. Q-Star Advance Project 31© Copyright, Confidential, Tata Motors Ltd MSAMSA MEASURE PHASE Date :- Part:- Part Type:- Parameter:- Specification:- Part A-1 A-2 A-3 B-1 B-2 B-3 C-1 0.3 C-3 Ref. Value 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1 6 1 1 1 1 1 1 1 1 1 1 7 1 1 1 1 1 1 1 1 1 1 8 1 1 1 1 1 1 1 1 1 1 9 0 0 0 0 0 0 0 0 0 0 10 0 0 0 0 0 0 0 0 0 0 11 1 1 1 1 1 1 1 1 1 1 12 0 0 0 0 0 0 0 0 0 0 13 1 1 1 1 1 1 1 1 1 1 14 1 1 1 1 1 1 1 1 1 1 15 1 1 1 1 1 1 1 1 1 1 16 1 1 1 1 1 1 1 1 1 1 17 1 1 1 1 1 1 1 1 1 1 18 1 0 0 1 0 0 0 0 0 0 19 0 0 0 0 0 0 0 0 0 0 20 1 1 1 1 1 1 1 1 1 1 21 0 0 0 0 0 0 0 0 0 0 22 1 1 1 1 1 1 1 1 1 1 23 1 1 1 1 1 1 1 1 1 1 24 1 1 1 1 1 1 1 1 1 1 25 1 1 1 1 1 1 1 1 1 1 Attribute Last Calibration:- NA WELD SHOP DEFECTS Calibration Status:- OK Anand Gurdeep Hargovind 5-Aug-14 Gauge: NA NA Gauge No.:- NA NA Calibration Frequency:- 6 MONTH CROSS TABULATION METHOD ATTRIBUTE STUDY 26 1 1 1 1 1 1 1 1 1 1 27 1 1 1 1 1 1 1 1 1 1 28 0 0 0 0 0 0 0 0 0 0 29 1 1 1 1 1 1 1 1 1 1 30 1 1 1 1 1 1 1 1 1 1 31 1 1 1 1 1 1 1 1 1 1 32 1 1 1 1 1 1 1 1 1 1 33 1 1 1 1 1 1 1 1 1 1 34 1 1 1 1 1 1 1 1 1 1 35 0 0 0 0 0 0 0 0 0 0 36 1 1 1 1 1 1 1 1 1 1 37 0 0 0 0 0 0 0 0 0 0 38 1 1 1 1 1 1 1 1 1 1 39 0 0 0 0 0 0 0 0 0 0 40 1 1 1 1 1 1 1 1 1 1 41 1 1 1 1 1 1 1 1 1 1 42 1 1 1 1 1 1 1 1 1 1 43 1 1 1 0 0 1 1 1 1 1 44 0 0 0 0 0 0 0 0 0 0 45 0 0 0 0 0 0 0 0 0 0 46 1 1 1 1 1 1 1 1 1 1 47 0 0 1 0 1 1 0 0 1 1 48 0 0 0 0 0 0 0 0 0 0 49 1 1 1 1 1 1 1 1 1 1 50 1 1 1 1 1 1 1 1 1 1
  30. 30. Q-Star Advance Project 32© Copyright, Confidential, Tata Motors Ltd MSAMSA MEASURE PHASE 0 1 0 1 39 1 40 38 2 40 10.93 29.07 40 10.40 29.60 40 2 108 110 1 109 110 30.07 79.933 110 28.60 81.40 110 41 109 150 39 111 150 41.00 109 150 39.00 111 150 P0 - Pe Po 0.98 P0 - Pe Po 0.98 1 - Pe Pe 0.61 1 - Pe Pe 0.61 Kappa 0.95 Kappa 0.95 Miss Rate 2.564103 False Alarm 1.80 0 1 0 1 39 2 41 38 3 41 11.21 29.79 41 10.66 30.34 41 2 107 109 1 108 109 29.79 79.207 109 28.34 80.66 109 41 109 150 39 111 150 41.00 109 150 39.00 111 150 P0 - Pe Po 0.97 P0 - Pe Po 0.97 1 - Pe Pe 0.60 1 - Pe Pe 0.61 Kappa 0.93 Kappa 0.93 Miss Rate 2.564103 False Alarm 2.70 0 1 0 1 40 0 40 39 2 41 10.93 29.07 40 10.66 30.34 41 1 109 110 0 109 109 30.07 79.93 110 28.34 80.66 109 41 109 150 39 111 150 41.00 109 150 39.00 111 150 P0 - Pe Po 0.99333333 P0 - Pe Po 0.986667 1 - Pe Pe 0.61 1 - Pe Pe 0.61 Kappa 0.98 Kappa 0.97 Miss Rate 0 False Alarm 1.80 kappa kappa Total Count Total Count Expected Count Expected Count 1 Count 1 Count Expected Count Expected Count Ref value Total A 0 Count C 0 Count Expected Count Expected Count kappa kappa A*C Cross Tabulation C Total C*Ref Value Cross Tabulation Total Count Total Count Expected Count Expected Count 1 Count 1 Count Expected Count Expected Count Ref value Total B 0 Count B 0 Count Expected Count Expected Count kappa kappa B*C Cross Tabulation C Total B*Ref Value Cross Tabulation 1 Count Expected Count Expected Count Total Count Total Count Expected Count Expected Count A 0 Count A 0 Count Expected Count Expected Count 1 Count A*B Cross Tabulation B Total A*Ref Value Cross Tabulation Ref value Total
  31. 31. Q-Star Advance Project 33© Copyright, Confidential, Tata Motors Ltd MSAMSA MEASURE PHASE CONCLUSION : Target A B C kappa > 0.75 0.95 0.93 0.97 Miss Rate Max 2% 2.56 2.56 0.00 False Alarm Max 6% 1.80 2.70 1.80 0.98 0.97 0.99 0.03 0.027 0.02 0.03 0.000 0.00 Effectiveness Pfa PM
  32. 32. Q-Star Advance Project 34© Copyright, Confidential, Tata Motors Ltd DEFECT CONTRIBUTION 34 2 1 3 1 2 3 S.N. PROBLEM % 1 FRT STUD 60% 2 CENTER STUD 10% 3 JACK MTG 30% MEASURE PHASE
  33. 33. Q-Star Advance Project 35© Copyright, Confidential, Tata Motors Ltd I SUB FRAME DIM SPECIFICATION B 826 C 710 D 50 E 50 F 50 G 80 H 974 I 761 B AD C F G E H Points Dimension A 710 MEASURE PHASE
  34. 34. Q-Star Advance Project 36© Copyright, Confidential, Tata Motors Ltd SUB FRAME DIM MEASUREMENTSUB FRAME DIM MEASUREMENT MEASURE P O I N T SP EC. SB NO. 937 15 SB NO. 937 16 SB NO. 9371 7 SB NO. 9371 8 SB NO. 937 19 SB NO. 937 20 SB NO. 9372 1 SB NO. 9372 2 SB NO. 9372 3 SB NO. 93724 A 710 708 709 707 708 709 707 709 708 706 707 B 826 824 823 425 826 825 824 825 823 824 824 C 710 710 710 709 708 709 710 709 710 708 709 D 50 49 51 50 50 49 50 49 50 50 50 E 50 50 50 49 50 50 49 49 50 50 49 F 50 50 49 50 50 50 50 50 49 50 50 G 80 79 80 79 80 80 80 80 80 79 80 H 974 972 971 973 972 974 973 972 972 973 973 I 761 761 760 761 759 759 758 758 759 759 758 I B A D C F G E H ALL DIM MEASURED IN mm BY MEASURING TAPE .ALL DIM MEASURED IN mm BY MEASURING TAPE .
  35. 35. Q-Star Advance Project 37© Copyright, Confidential, Tata Motors Ltd 1st Step : -CMM Report Part Level (Before ) MEASURE & ANALYZE PHASE
  36. 36. Q-Star Advance Project 38© Copyright, Confidential, Tata Motors Ltd FRAME SPECIFICATION H BA D C F G E B 826 C 710 D 50 E 50 F 50 G 80 H 974 Points Dimension A 710 MEASURE
  37. 37. Q-Star Advance Project 39© Copyright, Confidential, Tata Motors Ltd FRAME OBSERVED DATA MEASURE & ANALYZE PHASE P O I N T SPE C. FRA ME NO. 570 7 FRA ME NO. 5708 FRA ME NO. 5709 FRA ME NO. 5710 FRA ME NO. 5711 FRA ME NO. 5713 FRA ME NO. 5714 FRA ME NO. 5715 FRA ME NO. 5716 FRA ME NO. 5718 A 710 710 711 713 712 712 711 712 712 711 712 B 826 825 823 424 826 824 823 824 824 823 824 C 710 709 708 709 708 709 708 708 709 710 709 D 50 50 49 50 50 49 50 49 49 50 50 E 50 50 48 49 50 50 49 49 50 49 48 F 50 50 49 50 50 50 50 50 50 50 50 G 80 79 80 79 80 80 80 80 80 80 80 H 974 974 977 975 978 977 976 975 976 975 975 A B C D E F G H
  38. 38. Q-Star Advance Project 40© Copyright, Confidential, Tata Motors Ltd 40 40 S.NO. POINT NO. AXIS NOMINAL LH NOMINA L RH ERROR LH ERROR RH ERROR LH ERROR RH X -78 -78 -0.58 -1.61 -0.84 -0.75 A Y -355 355 0.26 0.6 0.11 0.66 Z -102.5 -102.5 -0.79 1.04 -1.23 -2.21 X 285 285 -0.59 -1.7 -1.59 -2.23 B Y -355 355 -1.45 -1.22 1.03 0.84 Z -110.5 -110.5 -2.88 -0.81 -0.84 -3.82 X 507.5 507.5 0.69 -2.81 -1.29 -2.35 C Y -355 355 -2.41 -1.77 0.27 -0.52 Z -122.5 -122.5 -3.16 -1.01 -3.44 -3.46 X 587.5 587.5 -0.23 -1.76 -2.19 -2.83 D Y -355 355 -1.92 -2.01 0.15 0.06 Z -122.5 -122.5 -3.59 -1.66 -3.66 -3.68 X 91 91 -1.2 -2.48 -1.75 -1.52 8 Y -412.95 412.95 -2.44 1.88 -2.23 2.83 Z -102.5 102.5 -1.38 0.67 -3.19 -2.7 X 507.5 507.5 -1.38 -2.59 -1.62 -2.56 9 Y -304.72 405.28 -1.59 -2.14 0.26 0.2 Z -122.5 -122.5 -4.57 -1.1 0.96 -0.28 X 587.5 587.5 -1.59 -1.58 -1.1 -1.55 10 Y -304.72 405.28 -1.48 -2.54 2.35 -1.99 Z -122.5 -122.5 -2.97 -2.05 0.37 -1.14 X -78 -78 -0.88 -2.11 -1.29 -2.55 11 Y -304.66 -304.66 1.62 -2.94 1.44 -3.16 Z -102 -102 0.39 0.57 -1.91 -0.92 SUPER ACE FRAME CMM REPORT P1423822 (14.08.2014) P1422978 (06.08.2014) 6 8 4 1 7 2 SUB FRAME MTG 3 5 Frame CMM Report
  39. 39. Q-Star Advance Project 41© Copyright, Confidential, Tata Motors Ltd Analyze & Improve
  40. 40. Q-Star Advance Project 42© Copyright, Confidential, Tata Motors Ltd Why –Why 1: Sub frame hole mismatch with frame nut Why –Why 2: Position of holes in sub frame shifted Why –Why 3: Sub frame dimension not ok as per CMM Why –Why 4: Position of locating pin shifted in Sub frame welding fixture. 42 Root Cause:- Locating pin shifted in Sub frame welding fixture WHY WHY ANALYSIS - 1
  41. 41. Q-Star Advance Project 43© Copyright, Confidential, Tata Motors Ltd LH side bkt position shifted in +Y dir by 2.0 mm. RH side bkt position shifted in +Y dir by 2.0 mm. Correction on Side member for Sub frame mtg at M/S Autoline IMPROVE PHASE
  42. 42. Q-Star Advance Project 44© Copyright, Confidential, Tata Motors Ltd Jack Mtg. Hole position LH shifted in +Y direction by 2.0 mm Correction on Assy subframe at BIW 1C Jack Mtg. Hole position RH shifted in +Y direction by 2.0 mm IMPROVE PHASE
  43. 43. Q-Star Advance Project 45© Copyright, Confidential, Tata Motors Ltd 45 CMM Report Part Level ( After ) IMPROVE PHASE
  44. 44. Q-Star Advance Project 46© Copyright, Confidential, Tata Motors Ltd 46 LH side bkt position corrected in X dir by +2.0 mm. RH side bkt position corrected in X dir. By – 2.0 mm LH side bkt position corrected in X dir by -2.0 mm. RH side bkt position corrected in X dir. By + 2.0 mm LH side bkt position corrected in X dir by 2.0 mm. RH side bkt position corrected in X dir. By – 2.0 mm Correction on frame at Supplier IMPROVE PHASE
  45. 45. Q-Star Advance Project 47© Copyright, Confidential, Tata Motors Ltd 47 LH side bkt position corrected in X dir by 2.0 mm. RH side bkt position corrected in X dir. By – 2.0 mm Correction on frame Jack Mtg. point at Supplier IMPROVE PHASE
  46. 46. Q-Star Advance Project 48© Copyright, Confidential, Tata Motors Ltd 48 48 CMM Report Frame (After Improvement) S.NO. POINT NO. AXIS NOMINAL LH NOMINAL RH ERROR LH ERROR RH ERROR LH ERROR RH X -78 -78 -0.2 -0.66 0.49 0.17 A Y -355 355 0.84 -0.55 1.15 1.03 Z -102.5 -102.5 1.19 1.94 0.57 1.04 X 285 285 -0.08 -1.19 0.54 -0.01 B Y -355 355 -0.29 -0.35 0.13 0.81 Z -110.5 -110.5 0.04 -0.61 -1.75 -0.69 X 507.5 507.5 0.21 -1.01 0.31 -0.33 C Y -355 355 -1.28 -0.74 -1.45 0.5 Z -122.5 -122.5 -0.54 2.35 0.02 -1.32 X 587.5 587.5 0.32 -1.01 -0.01 -1.03 D Y -355 355 -0.75 0.11 -1.1 0.77 Z -122.5 -122.5 1.62 -0.94 -0.36 -1.71 X 91 91 0.2 -1.45 0.33 -1.03 8 Y -412.95 412.95 -1.89 1.1 -1.06 0.74 Z -102.5 102.5 0.51 1.47 0.35 0.47 X 507.5 507.5 0.11 0.56 0.7 -0.85 9 Y -304.72 405.28 -0.39 1.03 -0.88 0.83 Z -122.5 -122.5 1.94 1.37 1.47 -1.89 X 587.5 587.5 0.36 -1.58 0.58 -1.02 10 Y -304.72 405.28 -0.33 0.09 -1.25 1.12 Z -122.5 -122.5 0.77 0.31 -1.87 X -78 -78 -0.6 -0.73 0.51 -1.54 11 Y -304.66 -304.66 1.26 -1.06 1.27 -1.2 Z -102 -102 1.35 -0.81 2.55 1.05 6 7 8 3 4 5 P1426791 (05.09.2014) P1427105 (10.09.2014) 1 SUB FRAME MTG 2 SUPER ACE FRAME CMM REPORT P1426791 (11.8.14) P1427105(14.8.14)
  47. 47. Q-Star Advance Project 49© Copyright, Confidential, Tata Motors Ltd 49 IMPROVE PHASE
  48. 48. Q-Star Advance Project 50© Copyright, Confidential, Tata Motors Ltd Why –Why 1: Sub frame hole mismatch with frame nut Why –Why 2: Sub frame twisted during coil spring fitment. Why –Why 3: Gap observed B/W resting block and sub frame during coil spring fitment process. Why –Why 4: Resting block wear out. 50 Root Cause:- Sub frame twisted due to resting block wear out. WHY WHY ANALYSIS - 2 Why –Why 4: Check point not availed for resting block condition in JH sheet.
  49. 49. Q-Star Advance Project 51© Copyright, Confidential, Tata Motors Ltd 51 DEVELOPMENT OF SOLUTION 710MM 705 MM Before fitment of coil spring DIM After fitment of coil spring Coil spring fitment with Sub Frame
  50. 50. Q-Star Advance Project 52© Copyright, Confidential, Tata Motors Ltd SUB FRAME DIM 710mmSUB FRAME DIM 710mm MEASURE & ANALYZE PHASE ALL DIM MEASURED IN mmALL DIM MEASURED IN mm
  51. 51. Q-Star Advance Project 53© Copyright, Confidential, Tata Motors Ltd 53 Resting block wear out leads to sub frame twisting New resting block installed DEVELOPMENT OF SOLUTION
  52. 52. Q-Star Advance Project 54© Copyright, Confidential, Tata Motors Ltd 54 IMPROVE PHASE
  53. 53. Q-Star Advance Project 55© Copyright, Confidential, Tata Motors Ltd Why –Why 1: Sub frame hole mismatch with frame nut. Why –Why 2: Sub frame long mbr twists after engine stuffing operation due to high twisting moment . Why –Why 3: Weight of Sub frame-engine assembly concentrated only on 2 studs Why –Why 4:Assembly mounted with only 2 studs before rest of the studs/bolts are mounted. 55 Root Cause:- Twisting of sub frame during engine stuffing due to the use of only 2 studs during the initial mounting process. WHY WHY ANALYSIS - 3 Why –Why 5: Insufficient gap for stud qualifying B/W Engine stuffing bed and sub frame.
  54. 54. Q-Star Advance Project 56© Copyright, Confidential, Tata Motors Ltd SUB FRAME ASSY PROCESS SEQUENCE (BEFORE) Two Center Stud (LH/ RH) used to mount the engine carrying sub frame Mounting of remaining 8 studs and 6 bolts was done after the engine stuffing process.
  55. 55. Q-Star Advance Project 57© Copyright, Confidential, Tata Motors Ltd SUB FRAME ASSY PROCESS SEQUENCE (AFTER) 2 Center studs+ 4 JACK Mtg studs + 4 FRONT Studs (LH/RH) are now mounted before the engine stuffing operation. Remaining 6 bolts are mounted after the engine stuffing process.
  56. 56. Q-Star Advance Project 58© Copyright, Confidential, Tata Motors Ltd CURRENT STATUS (AFTER IMPLEMENTATION)
  57. 57. Q-Star Advance Project 59© Copyright, Confidential, Tata Motors Ltd 59 Improvement Now stud qualifying is done before engine stuffing
  58. 58. Q-Star Advance Project 60© Copyright, Confidential, Tata Motors Ltd Improvement 60 BEFORE AFTER Hole side increase 13 mm to 16mm
  59. 59. Q-Star Advance Project 61© Copyright, Confidential, Tata Motors Ltd Improvement 61 BEFORE AFTER Sub frame Panel Side member LH hole size increase 11 mm to 12.5 mm
  60. 60. Q-Star Advance Project 62© Copyright, Confidential, Tata Motors Ltd Improvement 62 BEFORE AFTER Sub frame Panel Side member RH hole size increase 12.5 mm to 14.0mm
  61. 61. Q-Star Advance Project 63© Copyright, Confidential, Tata Motors Ltd 63 IMPROVE PHASE
  62. 62. Q-Star Advance Project 64© Copyright, Confidential, Tata Motors Ltd 64 TARGET ACHIEVED Sub Frame Rework % after improvement IMPROVE PHASEReworkin%
  63. 63. Q-Star Advance Project 65© Copyright, Confidential, Tata Motors Ltd Control
  64. 64. Q-Star Advance Project 66© Copyright, Confidential, Tata Motors Ltd Hard Control Soft Control • Frame critical DIM. Inspection Gauge made. • Frame critical DIM. Inspection Gauge made. • Calibration of welding fixture done • Trolley modification done to avoid transit damage. • Work Instruction Updated & display in shop floor • Check point added in JH sheet for resting block condition. • Die spotting & polishing frequency revised & added in Die History card • On job training provided to operators for Proper matching sub frame with frame. Way of Control Mechanism CONTROL PHASE
  65. 65. Q-Star Advance Project 67© Copyright, Confidential, Tata Motors Ltd STANDARDISATION 67 2 + Front stud 4 SMALL SIDE INTERNAL THREAD PNEUMATIC GUN LH & RH 4 JACK SMALL SIDE CONTROL PHASE
  66. 66. Q-Star Advance Project 68© Copyright, Confidential, Tata Motors Ltd 68 CONTROL PHASE JH CHECK SHEET
  67. 67. Q-Star Advance Project 69© Copyright, Confidential, Tata Motors Ltd BEFORE AFTER There was No gauge for checking sub frame dimension 710mm. Now we have gauge for checking sub frame dimension 710mm. BENEFITS:- Zero Rework , Quality improve , Cost & moral. 69 No Gauge for checking sub frame dimension. CONTROL PHASE
  68. 68. Q-Star Advance Project 70© Copyright, Confidential, Tata Motors Ltd BEFORE AFTER There was No gauge for checking frame dimension 710mm. Now we have gauge for checking frame dimension 710mm. BENEFITS:- Zero Rework , Quality improve , Cost & moral. 70 No Gauge for checking frame dimension. CONTROL PHASE
  69. 69. Q-Star Advance Project 71© Copyright, Confidential, Tata Motors Ltd 71 Frame to be check on checking fixture from supplier end. CONTROL PHASE
  70. 70. Q-Star Advance Project 72© Copyright, Confidential, Tata Motors Ltd 72 4 TIMES / SEASON BENEFITS Tangible Benefits:- We save rework manpower (2 in nos.) cost of 30000Rs. per month 30000 *12 (month)= 3,60,000 Rs. p.a. 4 Taps & 1 Conical bit per day (670Rs.) = 17420Rs. per month 17420* 12 (month) = 2,09,040 Rs. p.a. 4 Drill bits Cost per day (4900Rs.) = 127400Rs. per month 127400 * 12 = 15,28,800 Rs. p.a. Total Amount = 20,97,840 Rs. Per annum Cost saving of Rs 20.97 Lacs/ annum
  71. 71. Q-Star Advance Project 73© Copyright, Confidential, Tata Motors Ltd  Eliminate customer complain.  Improved presentation skill.  Improved analytical knowledge. 73 Intangible Benefits:- BENEFITS  Knowledge about 6 Sigma tools.  Improved team work & self confidence.
  72. 72. Q-Star Advance Project 74© Copyright, Confidential, Tata Motors Ltd YOUR ARE 74

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