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Brake drum project
This document describes a process modification to improve the brake drum assembly process. The original process had chamfering as a secondary operation, which could damage components and lead to rejections. The modified process moves chamfering earlier in the process flow. This allows for in-process inspection of all parameters, prevents component damage, reduces rejections and costs, and improves quality and productivity. A pilot lot was submitted to the customer demonstrating the benefits of the new process flow.
Brake drum project
- 1. PROCESS FLOW MODIFICATION IN BRAKEDRUM ASSEMBLY BY S.DEEPANATHAN
- 2. PROBLEM DEFINITION ChamferingOperation is carried out before machining. Machined components moved to the secondary operations may damage. 100% inspection cannot be done for all parameters during In-process.
- 3. KAIZEN THEME ContinualImprovement How many places this kaizen can be deployed horizontally? What modification can be done? How it improves the Process?
- 4. ACTUAL PROCESS FLOWDIAGRAM RAW MATERIAL INGOTS & MELTING IN FURNACE CASTINGS FETTLING DRILLING & TAPPING CNC MACHINING & BUSH PRESSING CHAMFERING INPROCESS INSPECTION FINAL INSPECTION PACKING & DISPATCH
- 5. DISADVANTAGES DUE TOTHIS PROCESS: Castings are getting damaged. As defined by the customer outer diameter is the critical parameter, it was being affected due to this process flow. In-House major rejection. Unnecessary movement of components. Dust formation in machined components. As chamfering was a secondary operation it cannot be included as in-process inspection.
- 6. Ishikawa analysis INADEQUAT E TRAINING COMPONEN TS NOT ARRANGED CASTINGS DAMAGED UNNECESSA RYFLOW MAJOR REJECTION S UNNECESSA RY MOVEMENTCOMPONEN TS NOT ARRANGED MISSING OPERATION S CHAMFERIN G MACHINE BED NOT CLEANED CHAMFERING MACHINE BED NOT CLEANED BINS SHORTAG E
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- 8. MODIFIED PROCESS FLOWDIAGRAM RAW MATERIAL INGOTS & MELTING IN FURNACE CASTINGS FETTLING DRILLING & TAPPING CHAMFERING CNC MACHINING & BUSH PRESSING INPROCESS INSPECTION FINAL INSPECTION PACKING & DISPATCH
- 9. ADVANTAGES OVER THISMETHOD Components are not damaged. Process flow can be much easier. Reduced In-House Rejection & cost. In-process inspection can be done for all parameters including chamfering. No dust formation in outer diameter.
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- 11. CONCLUSION Modified processflow intimated to the customer. Pilot Lot submitted to the customer with proper documents (P-PAP). Critical parameters are inspected and found to be Ok. Improved method on Quality and reduced rejections towards PPM.