This document summarizes an internship at a Toyota manufacturing plant for quality control. The internship objectives are to develop a defect data reporting and analysis system for manifold lines, assist with preparing for an upcoming TS16949 audit, gain exposure to other departments, take on additional responsibilities, and assist with new product development. Daily tasks include collecting and analyzing scrap data from various production lines, updating metrics and reports, attending scrap reduction meetings, performing process audits, and updating quality documents for the audit. The intern also creates reports on defect analysis, scrap levels, production outputs, and conducts a maintenance project template and Pareto analysis on defects. The internship provided experience with quality tools, standards, and processes as well as

1. QUALITY CONTROL INTERNSHIP
Samarth Patel
(847) – 644 – 5128
spate132@hawk.iit.edu
Final Year Graduate Student
Masters In Industrial Technology
& Management - Dec 2014
Bachelors In Mechatronics Engineering

2. Internship Objectives
Department Objectives
• Develop a system for reporting and analysis of internal defect data
for Toyota Manifold Lines.
• Assist in preparing Bloomingdale plant for upcoming TS16949
audit.
My Learning Objectives
• Would like to be exposed to other departments of the company.
• Want to develop myself by taking additional responsibilities.
• Assist in a new initiative undertaken by the company for a new
product development.

3. DAILY TASK
Collecting scrap data from Manifold and Case Lines
Updating data at the whiteboard with latest scrap and graphs.
Attend daily scrap reduction meeting to assist them with Counter-
Measures.
Entering data into the spreadsheet.
Monthly Production Vs Scrap Reports.
Performing Process Audits.

4. DAILY TASK
Updating quality documents for upcoming TS 16949 audit.
Assisting Team Leaders and Supervisor in their daily activities.
Assisting Production Mangers in making new graphs.
Data collection for new project or for a new material.

5. Daily Defect Analysis Case Lines

6. MONTHLY SCRAP REPORT CASE LINES

7. Daily Defect Analysis Spinner Lines

8. MONTHLY SCRAP REPORT SPINNER LINES

9. Daily Defect Analysis Manifold Lines

10. Monthly Manifold Scrap Report

11. SCRAP TRACKER

12. Daily Production PPH For SUBARU

13. Daily Production PPH For Honda 2GV

14. TS CERTIFIED Honda 2GV Inspection
Check Sheet

15. MANIFOLD REWORK DATA

16. MANIFOLD REWORK DATA

17. MAINTENANCE PROJECT
• Created a template for unused maintenance sheets.
• Real Time Analysis of the data with the help of built in complex Excel
Functions.
• Flow Chart Analysis of the top 3 defects.
• Formulae's used automatically identifies Top Defects and makes the
root cause analysis of that defect by taking the total number of
defects and dividing it into the individual production lines and further
dividing it into individual processes.
• Similar to Fishbone Diagram or Ishikawa Diagram.

18. PARETO ANALYSIS
• It is a statistical technique in decision making used for selection of a
limited number of tasks that produce significant overall effect. It uses
the 80-20 rule which in terms of quality can be applied as large
majority of problems (80%) are produced by a few key causes (20%).
• This Pareto Chart enables us to see what 20% of cases are causing
80% of the problem and where efforts should be focused to achieve
the greatest improvement.
• From this case we can see that we should focus much on Off-
Location, Burn Through and Out Of Spec Problem.

19. PARETO CHART TABLE
# CAUSE - CODE FREQUENCY
CUMMULATIVE
%
1 OFF-LOCATION – 5
62 28.6
2 BURN THROUGH –
3 61 56.7
3 OUT OF SPEC – 1
42 76.0
4 NO PENETRATION
-13 27 88.5
5 OTHER – 14
16 95.9
6 UNDER-CUT – 7
4 97.7
7 BACK BEAD – 10
3 99.1
8 COLD WELD – 6
2 100
9 PITTED WELD – 11
0 100
10 WELD LENGTH – 2
0 100
11 FLASH EXCESSIVE
– 4 0 100
12 PIN HOLES – 8
0 100
13 POROSITY – 9
0 100
14 QPR/QIR - 12
0 100

20. BREAKDOWN OF TOP 3 DEFECTS
OFF - LOCATION

21. BREAKDOWN OF TOP 3 DEFECTS
BURN -THROUGH

22. BREAKDOWN OF TOP 3 DEFECTS
OUT OF SPEC

23. Skill Development
Technical Skills Management Skills
- Communication
- Teamwork
- Interpersonal
- Self – Confidence
- Networking
- Being Proactive
- Making A-3 Report
- 5 Why Report
- Different types of Welding Process
- Basics Of Stamping
- Understanding on solving QPR
- and QIR
- Wide use of Excel to create Graphs.
- Toyota Engineering Standards
- Quality Documents such as Control
Plan (MQC), PFMEA ,Process Flow.
- Inventory Counting
- Sorting.
- Introduction to TS 16949.

24. Internship Effect
• The world of book is completely different than the
corporate world.
• Practical knowledge is much useful than theoretical
knowledge.
• Ability to learn something just by watching others.
• Never be afraid to speak of what you think.
• Use of 5-S in everyday life.
• Organizing your work and put a timeline to make your
work easier.
• Adding this experience to my resume will benefit me after
my studies.
• Allowed me to use the knowledge learned in class and put
it into test.

25. My 5 Year Plan
Supply Chain And
Logistics
Fundamentals
• EDX
• DEC 2014
Design Of Supply
Chain Systems
• EDX
• JUNE 2015
Supply Chain
Strategy
• EDX
• DEC 2015
Certified
Quality
Engineer
• ASQ
• DEC 2015
Six Sigma
Yellow Belt
• ASQ
• DEC 2015
Six Sigma
Green Belt
• ASQ
• DEC 2017
Six Sigma
Black Belt
• ASQ
• DEC 2019
Introduction To
Programming In
Python
• Coursera
• DEC 2014
Principles Of
Computing
• Coursera
• Class TBA
Algorithmic Thinking
• Coursera
• Class TBA

26. THANK YOU