This document summarizes a project to eliminate rejections at Operation 80 due to missing the cross oil hole operation. The project involved: 1) Implementing a poka-yoke (mistake-proofing device) in the form of a mechanical pin at Operation 75 to detect if the previous cross oil hole operation was missed. 2) Analyzing the manufacturing process and root causing the problem to human error where the operator was advancing the part without inspecting for completion of the cross oil hole operation. 3) Monitoring the effectiveness of the poka-yoke over time which showed that rejections at Operation 80 due to the missing cross oil hole operation were eliminated.

1. Elimination of Rejection at OP80
because of Cross oil hole opn. missing in
Camshaft Line
Project Done By: Kamlashish Goswami

2. 2 10/17/201
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Ashok Leyland Presentation (PNR)
1) Select the process
1.1 Select the process for improvement
considering the priority
- Rejection at OP80 ( cross oil hole position out )
FY13-14 DEFECT Feedback
1.2 Setting up target :Elimination of
Rejection at OP80 ( cross oil hole
position out)
Correct Oil
Hole
Position
Oil Hole
Position
shift
2.15mm shift
OK
Not OK

3. 3 10/17/201
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Ashok Leyland Presentation (PNR)
2) System Analysis
2.1 Clarify own process step :
Process at Camshaft machining
2.2 Check Defect Step:
Op. No. Op. Name
10 Facing & centering
20 Straightening
30 Rough Turning
40 Finish Turning
50 Key-way milling
60 Cam Milling
70 Gundrilling
80 Oil hole drilling
90 H.P. Washing
100 Induction Hardening
110 Tempering
120 Straightening
130 Recentering
140 Journal grinding
150 Cam Lobe grinding
160 Deburring
170 Crack detector
180 Intermediate washing m/c
190 Accurate Inspection
200 Lobe Lapping m/c
210 Phosphating Plant
220 Journal Lapping
230 Washing +Oiling
Failure Process
that makes In
process Defect
Operation missing
(No Poka-Yoke available to
prevent the opn. missing part
to move on the next opn.)

4. 4 10/17/201
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Ashok Leyland Presentation (PNR)
2) System Analysis Contd…
2.3 Clarify Occurrence condition:
Appearance
OP70 Gun drilling operation
Problem : Opn. Completion signal given
to m/c by operator without inspection
Manufacturing
Defective Condition
4M
Man (X)
No SOP available to start the
m/c after any interruption
Machine N/A
Method
(X)
Operation missing
 No Poka-Yoke available for
human error
Material N/A
2.4 Root Cause Analysis:
Occurrence Side:
Cross oil hole
position out Pre Gun
drilling opn.
missing
Part location
shift during FE
drilling
because of
hitting in
Rapid
Opn. Completion
signal given to m/c
by operator
without inspection
2.5 Problem Summary :
No Poka-Yoke
available to
detect the opn.
Miss part
Root Cause:

5. 5 10/17/201
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Ashok Leyland Presentation (PNR)
3) Poka-Yoke implementation Plan
3.1 Create Idea 3.2 Check Document reflection
Poka-Yoke Item Description Target
To provide the mechanical
pin at OP75 to detect the
opn. Missing part
Before- No feedback from OP75 (Orientation station) about
the previous operation missing
Finished
After- Mechanical pin provided to ensure the operation
completion up to 60mm depth to avoid the rejection at Op80
Mistake proofing sheet1. To provide the mechanical pin at OP75
to detect the opn. Missing part
Control Plan & WIS

6. 6 10/17/201
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Ashok Leyland Presentation (PNR)
Machining position shift on OP80
due to gun drill opn. Miss.
Before Improvement After Improvement
Status Before Improvement: Status After Improvement:
Poka-yoke Pin provided to detect the Gun
drill operation miss on orientation station
OP75.
Poke
Yoke Pin
No Poke
Yoke

7. 7 10/17/201
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Ashok Leyland Presentation (PNR)
Sustenance:

8. 8 10/17/201
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Ashok Leyland Presentation (PNR)
4) Confirmation
4.1 Time Study 4.2 Compliance
No impact in Time
Evaluation Item
(Opn.no80 Cross oil hole
miss)
Effectiveness monitoring
TotalAp
l’1
4
Ma
y’
14
Ju
ne
’1
4
Ju
ly’
14
Au
g’
14
Se
p’
14
Oc
t’
14
No
v’
14
De
c’
14
Ja
n’
15
Fe
b’
15
Ma
rc
h’
15
Ap
l’1
5
Ma
y’
15
Ju
ne
’1
5
Ju
ly’
15
Au
g’
15
Se
p’
15
Elimination of
rejection at OP80 due
to OP70 opn. missing
0 0 0 0 0 0 0 0 0 0 0 0 0 0 Finished
0 –OK X-NGOpn. No Target Result Judge
80 100% 100% 0

9. 9 10/17/201
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Ashok Leyland Presentation (PNR)
Updated Control Plan

10. 10 10/17/201
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Ashok Leyland Presentation (PNR)
Thanks