1. Shock Absorber
Quality Maintenance
Magneti Marelli Motherson Shock Absorbers India
Quality Control
Quality Maintenance – ACME PU1310
Project Leader – Sachin Dhawale
World Class Manufacturing

2. Shock Absorber
Proces
ses:
UnitCellProcess
UnitCell
Process
1 2 3 4
Nissan, GM, TML, Jamna All Models Front Strut Groove Dia U/S (A) 70
Nissan, FIAT All Models Gas Spring Groove Dia O/S (A) 70
FIAT Europe Fam A & B Rear Shocks Step Dia.Ø 7.92 O/S( (A) 40
FIAT Europe Fam A & B Rear Shocks Step Dia. Ø 7.92 U/S (A) 40
FIAT Europe Fam A & B Rear Shocks Binder 30
Punto RR, All Models Front Strut Upper Welding Blow hole 18
CriticalityIndex:
Customer
Model
Application
Occurance
Defects
4th QA Matrix 2014
Period SEP 2014 to DEC 2014 Plant - MMSA, Pune I
1301
Incoming
Material
1301 Incoming Material
4M
Process
Weightag
e(H,M,L)
2
4M - Machine
Project – ACME Improvement
Investigate current condition
Step 2 Step 3 Step 4 Step 5 Step 6 Step 7Step 1

3. Shock Absorber 3
4M - Machine
Project – ACME Improvement
Investigate current condition
Step 2 Step 3 Step 4 Step 5 Step 6 Step 7Step 1

4. Shock Absorber
Quality Maintenance
Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2
Investigating Current Condition
10.710.610.510.410.310.2
LSL USL
LSL 10.3
Target *
USL 10.7
Sample Mean 10.473
Sample N 50
StDev (Within) 0.119712
StDev (O v erall) 0.112418
Process Data
C p 0.56
C PL 0.48
C PU 0.63
C pk 0.48
Pp 0.59
PPL 0.51
PPU 0.67
Ppk 0.51
C pm *
O v erall C apability
Potential (Within) C apability
PPM < LSL 20000.00
PPM > USL 20000.00
PPM Total 40000.00
O bserv ed Performance
PPM < LSL 74210.28
PPM > USL 28965.82
PPM Total 103176.10
Exp. Within Performance
PPM < LSL 61914.04
PPM > USL 21730.43
PPM Total 83644.47
Exp. O v erall Performance
Within
Overall
Process Capability of Piston Groove Dia
Quality Maintenance

5. Shock Absorber
Quality Maintenance
Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2
Investigating Current Condition
7.9207.9047.8887.872
LSL USL
LSL 7.87
Target *
USL 7.92
Sample Mean 7.89592
Sample N 50
StDev (Within) 0.0136475
StDev (O v erall) 0.0161496
Process Data
C p 0.61
C PL 0.63
C PU 0.59
C pk 0.59
Pp 0.52
PPL 0.53
PPU 0.50
Ppk 0.50
C pm *
O v erall C apability
Potential (Within) C apability
PPM < LSL 80000.00
PPM > USL 40000.00
PPM Total 120000.00
O bserv ed Performance
PPM < LSL 28765.60
PPM > USL 38829.84
PPM Total 67595.44
Exp. Within Performance
PPM < LSL 54247.71
PPM > USL 67973.14
PPM Total 122220.85
Exp. O v erall Performance
Within
Overall
Process Capability of Piston End Dia
Quality Maintenance

6. Shock Absorber
Quality Maintenance
Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2
Restoration of Equipment to proper working condition for known causes
Groove stopper bolt changed, to avoid groove dia (Ø 10.3
±0.2) oversize & undersize problems
To avoid fall of burr on bolt, oil pipe fitted & oil
sprinkles starts
All controls & its light restored Feeding roller changed

7. Shock Absorber
Quality Maintenance
Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2
Restoration of Equipment to proper working condition for known causes
Missing bolts fitted Main part counter restored
For better tool life monitoring part
counter fitted for each tool

8. Shock Absorber
Quality Maintenance
Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2
Restoration of Equipment to proper working condition for known causes
Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2
Restoration of Equipment to proper working condition for known causes
Month wise defect PPM
1. Light fitted inside of ACME Machine
2. OPL For Chamfer Damage
3. OPL For Piston End Dia
4. OPL For uneven Chamfer
5. Q Spot makes all required gauges available for
machine
6. Cpk of Piston Groove Dia = 2.15
7. Cpk of Piston End Dia = 2.19

9. Shock Absorber
Quality Maintenance
Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2
Restoration of Equipment to proper working condition for known causes
Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2
Restoration of Equipment to proper working condition for known causes

10. Shock Absorber
Quality Maintenance
Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2
Restoration of Equipment to proper working condition for known causes
Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2
Restoration of Equipment to proper working condition for known causes
CHECK
RESTORATION
OK

11. Shock Absorber
Quality Maintenance
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
Investigate Current Conditions
Clarify the relationship among
Quality characteristics,
equipment and operation
method
Restoration of equipment to proper working
conditions for the known causes
.. Investigation of 4M Conditions, table of
the countermeasures against the defects
Factor analysis of the unknown causes
.. Processing Point Analysis (PPA)
Reducing and Eliminating all possible causes of
chronic losses
Restoration of equipment based on PPA
.. Checking the result of PPA
Establishment of proper conditions for zero defect
Establishment of the inspection standard sheet
by taking proper inspection items into consideration
Maintenance of proper conditions for zero defect
Carrying daily inspection and schedule inspection
into effect based on the inspection standard sheet
.. QM Matrix
Improvement of Maintenance method of the conditions
for zero defect
Efficient time-saving checking of the optimal conditions
.. Trend Charts Etc.,
OK
NOK
CHECK

12. Shock Absorber
Quality Maintenance
Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2
Establishment of Proper Conditions of 0 Defect
Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2
Establishment of Proper Conditions of 0 Defect
QC
AM
EEM
X Matrix
As we observed towards main contributor for
defect generation is slider
Q
Component

13. Shock Absorber 13
4M - Machine
Project – ACME Improvement
Maintenance of proper condition for zero defect
Step 2 Step 3 Step 4 Step 5 Step 6 Step 7Step 1
SAF
LCS
Date: 07/01/2014
Author: Kumbhar
One Point Lesson (OPL )
Plant: MMMSAI, RSA Center/Unit: RSA Department: Production Zone/ETU:Piston Rod
NOT OK
Not ok position of oil pipe,
which flow goning towards
other direction of tool
OK
OK position of oil pipe,
which flow goning towards
tool
PM
Other
Area/Team: Manufacturing Station: ACME Gindley Model/Product All Other:
Pillar
CD FI AM WO QC Source: OPL N°:
M13_00943EEM EPM PD EN ENV
Title: Wearing of protection gloves
NOT OK OK
SAF
LCS
Date: 07/01/2014
Author: Kumbhar
Title: Wearing of protection gloves
NOT OK OK
NOT OK
No washer clip to the air pressure pipe
OK
Washer clip to the air pressure pipe
QC Source: OPL N°:
M13_00943EEM EPM PD EN ENV Other
Pillar
CD FI AM WO PM
One Point Lesson (OPL )
Plant: MMMSAI, RSA Center/Unit: RSA Department: Production Zone/ETU:Piston Rod Area/Team: Manufacturing Station: ACME Gindley Model/Product All Other:
OPL
Updation:
 “Q’’ Component slider
 Lubrication oil & Cutting oil
 Insert (Tool)
AM Calendar
QC
AM
PM
EEM

14. Shock Absorber
Quality Maintenance
Parameters
Reference (value)
Tollerance
Measuring Tool
Frequency
Responsibility
Standard Document
Q POINT
H
M
L
Part Counter Reflecto meter
ForFamA1000
rods
ForFamB600
rods
5-7%
Contamination
WheelBalancing
Alignmentof
unloading
conveyor
Rodpass
throughcenter
Dressing
Frequency
OilLevel
ToolLife
ToolLife
ToolLife
± 200 rods - - - -
100mg/1000ltr
0.7micronmax
Electronic
Balance
Measuring
Visualy
Daily Daily Daily Daily Daily
Grinding
Wheel
Coolent
Coolent
Grinding
Wheel
Unloading
Conveyor
CincinatiGrinding
CincinatiGrinding
CincinatiGrinding
CincinatiGrinding
Swanson
Group Machine
OperatorOperator Operator Chemical Lab
Millipore Test
Component
Standard
Control Plan
Process Control
Sheet
Control Plan
Operator
√
-
Machine Start up
Checklist
100 % Visual
Inspection
100 % Visual
Inspection
100 % Visual
Inspection
100 % Visual
Inspection
Check
Impact
√ √ √
100 % Visual
Inspection
√ √ √
QM-
Matrix
√
ACMEGrindley
ACMEGrindley
ACMEGrindley
ACMEGrindley
ACMEGrindley
Grooving
Tool
RoughTool
Semifinish
Tool
FinishTool
PartingTool
Part Counter Part Counter Part Counter
ToolLife
ToolLife
3000
6000
2800
7500
3000
Operator Operator Operator
- - - - -
Part Counter Part Counter
100 % Visual
Inspection
100 % Visual
Inspection
100 % Visual
Inspection
Daily Daily Daily Daily Daily
Operator Operator
√
100 % Visual
Inspection
100 % Visual
Inspection
√
QM Matrix
Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2
Establishment of Proper Conditions of 0 Defect
Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2
Establishment of Proper Conditions of 0 Defect

15. Shock Absorber 15
4M - Machine
A) The settings are defined and shared. (1pt)
B) A method to check the settings is defined. (3pt)
C) The settings are easy to see without special
access or tools.(5pt)
A) Difficult to adjust/set.(1pt)
B) Easy to adjust/set.(3pt)
C) Adjustment is automatic.(5pt)
A) During the normal production (1pt)
B) Only at set up / start (3pt)
C) Exceptionally (5pt)
A) Low probability of seeing it. (1pt)
B) The periodic inspection system is able to detect
the variation. (3pt)
C) Continuous monitoring ensuring immediate alert.
(5pt)
A) Difficult, requiring specialized technical skills and
high downtime.(1pt)
B) Easy, once a person is qualified (3pt)
C) Automatic adjustment (closed loop). (5pt)
5
Questions
for 0
Defects
Are the equipment settings varying
outside the specification range?
5
Is it easy to bring the equipment
settings back into specification?
1 Are the settings defined?
4 Is the equipment variation detectable?
2
Is the machine easy to adjust to return
to specified range?
3
Parameters
Reference (value)
Tollerance
Measuring Tool
Frequency
Responsibility
Standard Document
Q POINT
H
M
L
Before After Before After Before After Before After Before After Before After
A) The settings are defined and shared. (1pt) 1 1 1 1 1 1
B) A method to check the settings is defined. (3pt)
C) The settings are easy to see without special
access or tools.(5pt)
5 5 5 5 5 5
A) Difficult to adjust/set.(1pt) 1 1 1 1 1 1
B) Easy to adjust/set.(3pt) 3 3 3 3 3 3
C) Adjustment is automatic.(5pt)
A) During the normal production (1pt) 1 1 1 1 1 1
B) Only at set up / start (3pt)
C) Exceptionally (5pt) 5 5 5 5 5 5
A) Low probability of seeing it. (1pt)
B) The periodic inspection system is able to detect
the variation. (3pt)
3 3 3 3 3 3
C) Continuous monitoring ensuring immediate alert.
(5pt)
5 5 5 5 5 5
A) Difficult, requiring specialized technical skills and
high downtime.(1pt)
B) Easy, once a person is qualified (3pt) 3 3 3 3 3 3
C) Automatic adjustment (closed loop). (5pt) 5 5 5 5 5 5
Total 9 23 9 23 9 23 9 23 9 23 9 23
% Q-Factor per Parameter 36.0% 92.0% 36.0% 92.0% 36.0% 92.0% 36.0% 92.0% 36.0% 92.0% 36.0% 92.0%
Daily
Operator
100 % Visual Inspection
√
ACMEGrindleyPartingToolToolLife3000
-
Part Counter
Operator Operator
100 % Visual Inspection 100 % Visual Inspection
- -
Part Counter Part Counter
Daily Daily
ACMEGrindley
ACMEGrindley
Semifinish
Tool
FinishTool
ToolLife
ToolLife
2800
7500
√
√ √ √
Impact
√
100 % Visual Inspection 100 % Visual Inspection 100 % Visual Inspection
4 Is the equipment variation detectable?
2
Is the machine easy to adjust to return
to specified range?
3
5
Is it easy to bring the equipment
settings back into specification?
QM-Matrix
Group Machine
Component
Standard
Check
1 Are the settings defined?
Are the equipment settings varying
outside the specification range?
ACMEGrindley
ACMEGrindley
ACMEGrindley
Grooving
Tool
RoughTool
PartingTool
ToolLife
ToolLife
ToolLife
3000
6000
3000
- - -
Part Counter Part Counter
Daily Daily
Part Counter
Operator
Daily
5
Questions
for 0
Defects
Operator Operator
Parameters
Reference (value)
Tollerance
Measuring Tool
Frequency
Responsibility
Standard Document
Q POINT
H
M
L
Before After Before After Before After Before After Before After Before After
A) The settings are defined and shared. (1pt) 1 1 1 1 1 1
B) A method to check the settings is defined. (3pt)
C) The settings are easy to see without special
access or tools.(5pt)
5 5 5 5 5 5
A) Difficult to adjust/set.(1pt) 1 1 1 1 1 1
B) Easy to adjust/set.(3pt) 3 3 3 3 3 3
C) Adjustment is automatic.(5pt)
A) During the normal production (1pt) 1 1 1 1 1 1
B) Only at set up / start (3pt)
C) Exceptionally (5pt) 5 5 5 5 5 5
A) Low probability of seeing it. (1pt)
B) The periodic inspection system is able to detect
the variation. (3pt)
3 3 3 3 3 3
C) Continuous monitoring ensuring immediate alert.
(5pt)
5 5 5 5 5 5
A) Difficult, requiring specialized technical skills and
high downtime.(1pt)
B) Easy, once a person is qualified (3pt) 3 3 3 3 3 3
C) Automatic adjustment (closed loop). (5pt) 5 5 5 5 5 5 Before After
Total 9 23 9 23 9 23 9 23 9 23 9 23 54 138
% Q-Factor per Parameter 36.0% 92.0% 36.0% 92.0% 36.0% 92.0% 36.0% 92.0% 36.0% 92.0% 36.0% 92.0% 36.0% 92.0%
Daily
Operator
100 % Visual Inspection
√
ACMEGrindleyPartingToolToolLife3000
-
Part Counter
Operator Operator
100 % Visual Inspection 100 % Visual Inspection
- -
Part Counter Part Counter
Daily Daily
ACMEGrindley
ACMEGrindley
Semifinish
Tool
FinishTool
ToolLife
ToolLife
2800
7500
Total Machine
Q-Factor
√
√ √ √
Impact
√
100 % Visual Inspection 100 % Visual Inspection 100 % Visual Inspection
4 Is the equipment variation detectable?
2
Is the machine easy to adjust to return
to specified range?
3
5
Is it easy to bring the equipment
settings back into specification?
QM-Matrix
Group Machine
Component
Standard
Check
1 Are the settings defined?
Are the equipment settings varying
outside the specification range?
ACMEGrindley
ACMEGrindley
ACMEGrindley
Grooving
Tool
RoughTool
PartingTool
ToolLife
ToolLife
ToolLife
N° of
parameters
3000
6000
3000
6
- - -
Part Counter Part Counter
Daily Daily
Part Counter
Operator
Daily
5
Questions
for 0
Defects
Operator Operator
5 Question for Zero defect
QC
AM
PM
EEM
Project – ACME Improvement
Improvement of Maintenance methods of conditions for 0 Defect
Step 2 Step 3 Step 4 Step 5 Step 6 Step 7Step 1
B/C 5.6

16. Shock Absorber 16
4M - Machine
Project – ACME Improvement
Improvement of Maintenance methods of conditions for 0 Defect
Step 2 Step 3 Step 4 Step 5 Step 6 Step 7Step 1
SAF
LCS
Date: 07/01/2014
Author: Kumbhar
One Point Lesson (OPL )
Plant: MMMSAI, RSA Center/Unit: RSA Department: Production Zone/ETU:Piston Rod
NOT OK
Not ok position of oil pipe,
which flow goning towards
other direction of tool
OK
OK position of oil pipe,
which flow goning towards
tool
PM
Other
Area/Team: Manufacturing Station: ACME Gindley Model/Product All Other:
Pillar
CD FI AM WO QC Source: OPL N°:
M13_00943EEM EPM PD EN ENV
Title: Wearing of protection gloves
NOT OK OK
SAF
LCS
Date: 07/01/2014
Author: Kumbhar
Title: Wearing of protection gloves
NOT OK OK
NOT OK
No washer clip to the air pressure pipe
OK
Washer clip to the air pressure pipe
QC Source: OPL N°:
M13_00943EEM EPM PD EN ENV Other
Pillar
CD FI AM WO PM
One Point Lesson (OPL )
Plant: MMMSAI, RSA Center/Unit: RSA Department: Production Zone/ETU:Piston Rod Area/Team: Manufacturing Station: ACME Gindley Model/Product All Other:
ISSUER /
DEPARTMENT
DATA
X
X X
YES NO SIGN
NAME
STANDARDIZATION
EXTENSION OF
STANDARDIZATION
SPECIFICATIO
NS
0.5% TO 1.0% CUT MARK REJECTION
PERIOD INDICATORS OBSERVATION PERIOD INDICATORS OBSERVATION
4 MONTHS % REJECTION 10% TO 15% CUT MARK REJECTION 3 MONTHS % REJECTION
Proper size groove slider bolt
CONSTRUCTION VERIFICATION OPERATIONAL FEEDBACK
HISTORY RESULTS
X
ENVIRONMENT ERGONOMICS
PROBLEM SOLUTION
PURPOSE OF MODIFICATION IMPROVING MTBF / MTTR AND GERD
PHASE OF
CREATION
PLANNING CHECKLIST INSTALLATION VERIFICATION
IMPACT
RELIABILITY MAINTENANCE PRELIMINARY DESIGN VERIFICATION FUNCTIONAL VERIFICATION
QUALITY COST FINAL PROJECT VERIFICATION FINAL CHECK
OPERABILITY SAFETY
DESCRIPTION
Piston Rod ACME Grindley
05-2014
PRODUCTION
PROCESS
UPPER MOUNTING RING+DUST
SHIELD CAP+SHOX CO2 WELDING
DOCUMENT No.
(INDEX)
EQUIPMENT
LINE STATION BP SUPPLIER
Maintenance Prevention Information
ESTABLISHMENT PRODUCTION UNIT MMSAI -1302 PUNE
QC
AM
PM
EEM

17. Shock Absorbers
Quality MaintenanceQuality Maintenance
Thank You
Magneti Marelli Motherson Shock Absorbers India Pvt. Ltd.