This presentation is about the summer training project i had done in G-TIP alwar project title was quality in process.

1. Quality In Process
Name Shubham Jaswal
Roll no. Me/15/729G-TIP

2. Contents
 Introduction of company
 Structure of plant
 Production Technology Used
 Feasibility of project
 Requirement specification
 Approach for project
 Finding
 Conclusion
 Reference
July 17, 2019

3. Introduction
 G-TEKT, a specialized manufacturer of auto body components
and transmission parts.
 Established in 1952 and 1964 it started doing business with
Honda. Today G-Tekt operate 33 plant across globe.
 G-Tekt Indian plant(G -Tip) is established in 2011.
July 17, 2019

4. Introduction
 Advances given to Automobile Industry by G-tekt
Hot stamping Technology (Future)
how this technology will affect Automobile
industry?
 Customer of G-tekt across Globe.
Honda Motor Co., Ltd. (India) Toyota Motor Corporation
Subaru Corporation Mazda Motor Corporation
Nissan Motor Co., Ltd. Suzuki Motor Co. (India)
Jatco Ltd. Jaguar Land Rover Limited
BMW

5. Introduction
Running Projects in G-TIP
Honda city Honda All New Amaze
Honda Brio Honda Jazz
Honda WR-V Honda BR-V
Maruti Swift Maruti Wagon R etc.
Fig1
Parts
made
by
G-TIP

6. Structure of plant
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 Plant Layout:
Press lines
Four ADIA 200 tonne One ADIA 800 tonne
One 250 tonne One 3000 Tonne
One 1500 tonne One kawasaki hydraulic press
Fig.2
Shows the
part produced
by press

7. Structure of plant
 Weld Lines
A wide range of modern weld equipment comprising of
stationary and portable spot welding, MIG/Spot welding,
special purpose welding machine, jig and fixture.
1. 12 Robotic line (45 robots)
2. Subline (23 spot wield machine)
Fig. Spot
Wielding
machine

8. Production Technology Used in press
Mechanical vs Hydraulic
pressses

9.  Cold working
 Die
 Stroke of press machine
-selection of press machine
Production Technology Used in press
stroke
Tonnage
Fig 3 Stroke
tonnage curve

10. Production Technology Used in weld
 Spot Weld
?
 Mig Weld
?
Fig 4
Spot
JIG
Fig 5
MIG
Robot

11. Feasibility of project
In process Quality is practice of Quality Assurance .
 Importance of in process Quality
 Current Trends of in process Quality
 Quality system in Indian Companies
 Future scope of In process quality

12. Requirement specification
 5 Why analysis
- Importance of this principle
Important things to Remember why applying this
analysis
-Judge process not people
-You cannit blame human for error

13. Requirement specification
 Pre motion time study
-Role of this study in Keeping Quality
Example: operator working in a production line on a
particular day having lack of focus due to any reason.
Benefit of this Technique :-
 Improvement of productivity
 Improvement in quality
 Red Bin analysis

14. Approach for project
 Approach for project involves study of present quality
system employed in company, doing and watching red bin
analysis after end every working day.
Study of Present quality system in company
 Various type of sensor and guide are employed in both jig
and fixture for detection and prevention of defect.

15. Defect observed robotic wield shop
-Shifting of spot from original position
Reason-improper fixture locking
-improper fit in part placement
-Defect mainly observed in movable fixture line.
-Decrease in wield strength due to improper tip dressing.
- dent and scratch due to wield material collected on fixture
-NG parts undetected by failed sensor.
-nut thread damage due to extra pneumatic pressure.
Finding
Fig spot
Wield

16. Finding and suggestion
- Hammer test of spot after every hour.
-Weaking of spot after 80 spot wield.
- Hammer test when necessary
- Visual inspection and its marking (Nut, spot, etc.)
- Visual inspection by quality personal.
- - Every station is provided with diagram of NG and correct part
in detail like “defect found in this part” so as to help operator. –
- For failed sensor fixture should be regularly checked with NG
part after fixed time interval so that sensor should not pass an
NG part.
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17. Finding
 Problem with movable fixture
Regular breakdown
 Reason for movable fixture
safety
Solution1 stationary fixture (as light curtain are present for safety)
Solution2 the rail should be upgraded should be provided with
rack and pinon rail.
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Fig Movable
fixture

18. Finding
 Defect Reported in SSW line
- Wrong side nut
- Nut thread break
- Lack of wield strength (low pneumatic pressure)
-Opposite nut wielded
- Part get tilted due to fixture and wield burr inside the
wielded part requiring rework.
Solution
 Motion Time Study
 Advantage of Motion Time study
  it decrease chance of error due to lack of focus
  increases worker productivity time study
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19. Finding
 Advance technique for Quality assurance in line job rotation should
be done on regular bases so as to increase skill in operator and
flexibility in doing work.
Objective of Job Rotation
 Employee Learning
-Rotation making employees more versatile
-Gives employees a broader understanding of the business
allowing them to be better prepared to be promoted to management.
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20. Finding
 Employer Learning
Using job rotation employers can learn their individual
worker's strengths
Employers receive a flexible and knowledgeable workforce
that can be sourced throughout the company or agency.
 Employee Motivation
Rotation reduces boredom.
More knowledge of the company as a whole may lead to
more promotions
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21. Conclusion
 Pursuing my industrial training at G-TIP was very different
and learning experience of my life.
 The company had prioritized Quality and safety over
quantity. Technique of red bin analysis, kaizen, TPM, TQM
proves that Company is promised for quality. G-TIP is
regularly wining Honda best quality supplier award.
 In process quality is important aspect of Quality assurance it
decreases burdon on Quality control(inspection). In process
quality control directly help in achieving quality in process. If
quality in processes is better in increases chances of better
quality in product.
July 17, 2019Presentation on Forms of communication

22.  www.takao.co.uk
 www.g-tekt.jp
 http://www.g-tekt.de/en/company/g-tekt-corporation.html
http://gordon.tufts.edu/programs/m-s-in-engineering-
management/msem-vs-mba/
 https://quality-one.com/5s/
 https://www.adb.org/publications/five-whys-technique
July 17, 2019
References

23. CORE JAVA
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