2. Trelleborg Automotive India Pvt. Ltd
• ISO 14001
• OHSAS 18001
• TS 16949
• ISO 50001
• Ford Q1
• 100 % subsidiary of Trelleborg AB, Sweden
TRELLEBORG GROUP
3. Business Area of Trelleborg Group
TRELLEBORG GROUP
TRELLEBORG AUTOMOTIVE
4. Trelleborg Automotive
Biggest Non-Tyre Rubber Player
Founded in 1905
Employing 20,000 people
TRELLEBORG GROUP
TRELLEBORG AUTOMOTIVE
11. SUMMARY
QCC Name : Pryaas
Quality Circle Started : July 2012
QCC Completed : October 2012
Meeting Scheduled : Once a week
Meeting Day : Friday (2pm-4pm)
No of Meetings planned : 16
No of Meetings conducted : 16
Attendance : 98%
TRELLEBORG GROUP
12. Identification of Work
Related Problem
Tools:
Brainstorming Problem Data Bank
TRELLEBORG GROUP
13. Problems Identified through problem data bank in Bond Application shop
Major 09 Problems Identified
• Extra bond in AV 9000 outer - Category A Problem
• Extra bond in AV 0640 inner – Category A Problem
• Extra bond in AV 0650 outer – Category A Problem
• Extra bond in AV 2141 outer – Category A Problem
• Extra bond in AV 2151 outer – Category A Problem
• Extra bond in AV 1540 outer – Category B Problem
• Extra bond in AV 2500 outer – Category B Problem
• Extra bond in AV 1340 outer – Category B Problem
• Extra bond in AV 0290 outer – Category C Problem
TRELLEBORG GROUP
14. Selection of Problem
Tools:
Stratification Pareto Diagram Brainstorm
TRELLEBORG GROUP
15. Defect Categorizing
Defect Categorizing
The Problems are classified into the following categories:-
Category A - This can be solved with minimum involvement of other
department
Category B - Involvement of other department required
Category C - Management help is required
n
BC zatio
A ri
o
teg
Ca
TRELLEBORG GROUP
15
16. Stratification
No of ABC tion
Category i za
Problems Ca tegor
A 5
B 3
C 1
15
10
5
3
5
1
0
m
N
b
p
o
e
r
s
f
l
.
A B C
TRELLEBORG GROUP
17. Major quality defects in Metal Preparation (Bonding)
96 100
800 100
91
84
76
600 67 75
57
400 46 50
31
Q
R
y
e
t
j
255
%
m
C
u
e
v
a
t
i
l
200 25
120
92 82 78 66 54 45 30
0 0
0
0
0
9
V
A
4
6
0
V
A
0
5
6
0
V
A
4
1
2
V
A
1
5
1
2
V
A
0
4
5
1
V
A
0
0
5
2
V
A
0
4
3
1
V
A
0
9
2
0
V
A
TRELLEBORG GROUP
19. Activity Chart
QUALITY CIRCLE NAME DEPARTMENT FACILITATOR MEMBER
PRAYAAS METAL PREPARATION SAMBIT SAHA LEADER: MUNIRAJ
PROJECT REASON FOR SELECTION
Extra Bond on AV 9000 Outer To reduce Rejection Percentage on AV 9000 Outer MEMBER: PRADEEP JHA
MEETING DAY & TIME DATE OF BEGINNING DATE OF COMPLETION MEMBER: INDERJIT
MEMBER: TARUN KUMAR
Friday, ( 2 PM to 4 PM) 01-Jul-12 30-Oct-12 MEMBER: NEHA ARORA
A P July' 12 August' 12 September' 12 October' 12
Sl. No. Activity Week Status
C D 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
1 IDENTIFICATION OF PROBLEM
2 SELECTION OF PROBLEM PLAN
3 DEFINE THE PROBLEM
4 ANALYSE THE PROBLEM
5 IDENTIFICATION OF CAUSE
6 FINDING OUT THE ROOT CAUSE DO
7 DATA ANALYSIS
8 DEVELOPING THE SOLUTION
FORESEEING PROBLEM OF
9
RESISTANCE
CHECK
TRIAL IMPLEMENTATION & CHECK
10
PERFORMANCE
11 REGULAR IMPLEMENTATION
ACT
12 FOLLOW UP & REVIEW
TRELLEBORG GROUP PLAN ACTUAL DELAYED
19
21. Process Flow Sequence of Bonding on AV 9000 Outer
Bonding Fixture Primer Application
Parts loading in fixture
Unloading Drying Bond Application Drying
TRELLEBORG GROUP
22. Extra Bond over AV 9000 outer
Extra
Bond
Extra bonding causes:
1. Extra flash
2. Part fitment problem (internal)
3. Part fitment problem (customer)
TRELLEBORG GROUP
22 October 2, 2008
24. Observation & Data Collection for Rejection Analysis
Total Loss in Value
Months Rejection Qty % Rej. Target % Rej.
Production (Rs.)
January' 12 31542 876 2.78% 33215 0.50%
February' 12 30546 935 3.06% 34547 0.50%
March' 12 35476 852 2.40% 32547 0.50%
April' 12 34587 785 2.27% 32580 0.50%
May' 12 33658 654 1.94% 32340 0.50%
June' 12 32598 849 2.60% 31547 0.50%
TRELLEBORG GROUP
24 October 2, 2008
25. Rejection Analysis for Extra Bonding on AV 9000 outer
In part no. AV 9000 OUTER rejection was 2.51% from last four months due
to excess bond; leads to customer concerns
The rejection cost is approximate Rs. 32796/- per month.
TRELLEBORG GROUP
25 October 2, 2008
27. Cause & Effect Diagram
Machine Man
Needle Problem Wrong Bond Application
Air Pressure
Unclean Gun Table Problem Visual aids not clear
Foreign Particles No understanding of
Gun Nozzle damaged Pressure gauges
Moisture in
Airline Unskilled manpower
Stirrer not working Wrong fixture
used
Material Pressure AV 9000
EXTRA
BOND
Bond Viscosity Improper Fixture Design
Improper method
Wet part unloading of spray
Wrong
Mixing
Spray distance
Fixture Damage
Wooden Fixture Wrong
quantity of Wrong Variation in
thinner material loaded quantity
loading Wrong spray
angle
Material Method
TRELLEBORG GROUP
28. Finding out the Root
Cause
Tools:
Cause & Effect Diagram Brainstorm
TRELLEBORG GROUP
29. Gemba on Shop Floor
Sl. No. Probable Causes Who When Where How Qty. (Validated on 14thConclusion
Checked Result Aug’12)
1 Wrong Bond Application Pradeep DFT test 10 pcs. All pcs found Ok Not a cause
2 Visual aids not clear Tarun Visual Check - Clear & legible Not a cause
No understanding of pressure operators have clear
3 Inderjit Sample question - Not a cause
gauges knoledge
4 Unskilled operator Neha Sample Bonding 10 pcs. All pcs found Ok Not a cause
5 Wrong fixture used Pradeep Sample Bonding 10 pcs. All pcs found Ok Not a cause
6 Air Pressure Inderjit Pressure Gauge 10 pcs. Variation in 3 pcs Probable Cause
7 Unclean Gun Tarun DFT test 10 pcs. All pcs found Ok Not a cause
8 Foreign Particles Pradeep Sample Bonding 10 pcs. All pcs found Ok Not a cause
9 Moisture in Airline Muniraj Sample Bonding 10 pcs. All pcs found Ok Not a cause
10 Wooden fixture Muniraj Sample Bonding 10 pcs. Found Variation Probable Cause
11 Stirrer not working Inderjit During Bond Bond Sample Bonding 10 pcs. All pcs found Ok Not a cause
application Booth
12 Needle Problem Tarun Sample Bonding 10 pcs. All pcs found Ok Not a cause
13 Table Problem Neha Sample Bonding 10 pcs. All pcs found Ok Not a cause
14 Materuial Pressure Inderjit Pressure Gauge 10 pcs. Variation in 3 pcs Probable Cause
15 Gun nozzle damaged Neha Sample Bonding 10 pcs. All pcs found Ok Not a cause
16 Bond Viscosity Neha Viscometer once before bonding Found Variation Probable Cause
17 Wrong Mixing Pradeep Sample Bonding 10 pcs. All pcs found Ok Not a cause
18 Wrong quantity of thinner Muniraj Sample Bonding 10 pcs. All pcs found Ok Not a cause
Not possible to load
19 Wet part / wrong part loading Neha Sample Check - Not a cause
wrong parts
20 Wrong spray angle / distance Tarun Sample Check 10 pcs. All pcs found Ok Not a cause
21 Improper Fixture Design
TRELLEBORG GROUP
Muniraj - - Found Variation Probable Cause
29
30. Cause & Effect Diagram
Machine Man
Needle Problem Wrong Bond Application
Air Pressure
Unclean Gun Table Problem Visual aids not clear
Foreign Particles No understanding of
Gun Nozzle damaged Pressure gauges
Moisture in
Airline Unskilled manpower
Stirrer not working Wrong fixture
used
Material Pressure AV 9000
EXTRA
BOND
Bond Viscosity Improper Fixture Design
Improper method
Wet part unloading of spray
Wrong
Mixing
Spray distance
Fixture Damage
Wooden Wrong
Fixture quantity of Wrong Variation in
thinner material loaded quantity
loading Wrong spray
angle
Material Method
TRELLEBORG GROUP
31. Possible / Suspected Root Causes
Air Pressure
Material Pressure
Bond Viscosity
Wooden Fixture
Improper Fixture Design
TRELLEBORG GROUP
31 October 2, 2008
32. Data Analysis
Tools:
Why – Why Analysis Brainstorm
TRELLEBORG GROUP
33. Validation of Suspected Root Causes
1. Rejection Data after change in Bonding Air Pressure
Air Pressure Rejected
No. of Pcs OK Pcs Reasons
(kg) Pcs
10 4 9 0
10 4.5 9 1 Colour changed to Yellow
10 5 10 0
10 5.5 10 0
10 6 9 1 Bond entered into the hole
Conclusion:
No effect of changing in Air Pressure. This is not a Cause.
TRELLEBORG GROUP
33
34. Validation of Suspected Root Causes
2. Trial Result on Bond Viscosity
Viscosity
No. of Pcs OK Pcs Rejected Pcs Rejection (%)
(sec)
50 23 48 2 4%
50 21 50 0 0%
50 19 50 0 0%
50 15 49 1 2%
Conclusion:
No effect of changing in Bond Viscosity. This is not a Cause.
TRELLEBORG GROUP
34
35. Validation of Suspected Root Causes
3. Trial Result after change in Material Pressure
Material
No. of Pcs Pressure OK Pcs Rejected Pcs Rejection (%)
(kg/cm2)
50 1.5 50 0 0%
50 2.0 50 0 0%
50 2.5 50 0 0%
50 2.2 48 2 4%
Conclusion:
No effect of changing in Material Pressure. This is not a Cause.
TRELLEBORG GROUP
35
36. Validation of Suspected Root Causes
4. Trial Result after changing the fixture material to Nylon
Side cover has been given &
fixture material changed to Nylon
Eliminates extra bond on side faces,
but extra bond on collar continues
Extra bond
Conclusion:
Changes in fixture material also gave the same kind (extra bond)
of rejection. There’s a tendency of bent in Nylon fixture also,
36
which leads to extra bond on side faces again on longer run.
TRELLEBORG GROUP
37. Validation of Suspected Root Causes
5. Unbalancing of plates during movement of material on conveyor and
bonding because of improper fixture design
Extra Bond on AV 9000 Outer Why – Why
Why – Why
Why Analysis
Analysis
Outer surface area wasn’t properly masked
Why
Three was no cover at the sides
Why
Improper Fixture Design Wrong Method
Wrong Method
Why
used
used
Conclusion:
Wrong method have been used for Bonding on AV 9000 outer.
TRELLEBORG GROUP
37
38. Developing the Solution
& Feasibility Study
Tools:
Knowledge Skills Experience Team Spirit
TRELLEBORG GROUP
39. Feasibility Study
We have used wrong method of Bonding. Manual mode has to be
avoided.
Trial had been taken on Existing Rotary machine (Full Auto)
There were no extra bonds on outer faces & collar on AV 9000 after trail
run
OK
Parts
Part has to be fixed into the Fixtures on rotary Machine
TRELLEBORG GROUP
39
40. Solution Development
Existing Fixtures have key-chuck & it takes extra time for setting change
Parts fixed into the fix diameter fixtures on Rotary Machine
BEFORE AFTER
Have key-chuck Fix-chuck
TRELLEBORG GROUP
40
42. Foreseeing Problems
SL. Possible Probable Status against Proposed
Root Cause
No. Solutions Resistance Resistance Solution
Not agreed by
Parts should be
Cycle time / part Industrial
Clamp parts into clamped such a
Improper Fixture has been Engineering
1 the fixtures on way that 3 parts
Design increased to 11 department as
Rotary can be clamped
sec. from 6 sec. cycle time has
vertically
been increased
TRELLEBORG GROUP
42
44. Trial Implementation – Proposed Solutions
SL. Possible / Proposed Trial
Results Conclusion
No. Solution Implementation
The lower most part
wasn't properly Fixtures should be
Clamps made such a
bonded. But The made such a way
Clamp parts into the way that 3 outer can
1 upper one & that 2 outer parts
fixtures on Rotary be fixed in one
medium part were can be bonded
fixture vertically
uniformly bonded as uniformly
per specification
44
45. Cycle Time Observation during Trial Implementation
Manual Bonding Fixtures with key chuck Fixtures with fixed chuck
Operation Time (sec) Operation Time (sec) Operation Time (sec)
Loading 30 Primer / Bond 11 Primer / Bond 11
Primer 45 Setting change 5
Bond 50
Unloading 25
Total Cycle Total Cycle Total Cycle
150 16 11
Time Time Time
Parts / fixture 25 Parts / fixture 1 Parts / fixture 1
Cycle Time / Cycle Time / Cycle Time /
6 16 11
part (Outer) part (Outer) part (Outer)
3 parts clamped in one fixture 2 parts clamped in one fixture
Operation Time (sec) Operation Time (sec)
Primer / Bond 11 Primer / Bond 11
Total Cycle Time 11 Total Cycle Time 11
Parts / fixture 3 Parts / fixture 2
Cycle Time / Cycle Time /
3.7 5.5
part (Outer) part (Outer)
TRELLEBORG GROUP
45
46. Action Plan – Final Solution
SL.
Final Solution Target Date Responsibility Status
No.
Fixtures should be
made such a way
Amit Solanki &
1 that 2 outer parts 15-Oct-12 Implemented
Nishesh Tripathi
can be bonded
uniformly
TRELLEBORG GROUP
46
47. Effectiveness Check after Implementing Solutions
Rejection% of Extra Bond has dropped down to Zero percentage
Overall Rejection cost on October’12 has been reduced
92.67% than September’ 12
TRELLEBORG GROUP
47
49. Standardization of Action
SL.
Description What Where When Who Status
No.
Changes in Process
1 Process PFD 15-Oct-12 IE Done
Flow Diagram
Failure Mode analysis
2 for the modified Failure Mode Analysis PFMEA 15-Oct-12 IE Done
process step
3 Changes in Control Plan Process Sheet Control Plan 15-Oct-12 Quality Done
Online Inspection
(Viscosity & DFT) in
4 Rotary for AV 9000 Inspection Sheet Rotary 15-Oct-12 Quality Done
outer instead of
Bonding booth
Detailed modified
5 One Point Lesson (OPL) Rotary 15-Oct-12 IE, Process Done
process
Work Instruction for Standard Operating
6 Rotary 17-Oct-12 IE Done
the modified process Procedure (SOP)
OK & NG Sample to be
7 OK & Not-OK Parts Rotary 17-Oct-12 Quality Done
kept
TRELLEBORG GROUP
49
50. Review of Activity Chart ~ Plan v/s Actual
QUALITY CIRCLE NAME DEPARTMENT FACILITATOR MEMBER
PRAYAAS METAL PREPARATION SAMBIT SAHA LEADER: MUNIRAJ
PROJECT REASON FOR SELECTION
Extra Bond on AV 9000 Outer To reduce Rejection Percentage on AV 9000 Outer MEMBER: PRADEEP JHA
MEETING DAY & TIME DATE OF BEGINNING DATE OF COMPLETION MEMBER: INDERJIT
MEMBER: TARUN KUMAR
Friday, ( 2 PM to 4 PM) 01-Jul-12 30-Oct-12 MEMBER: NEHA ARORA
A P July' 12 August' 12 September' 12 October' 12
Sl. No. Activity Week Status
C D 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
1 IDENTIFICATION OF PROBLEM
2 SELECTION OF PROBLEM PLAN
3 DEFINE THE PROBLEM
4 ANALYSE THE PROBLEM
5 IDENTIFICATION OF CAUSE
6 FINDING OUT THE ROOT CAUSE DO
7 DATA ANALYSIS
8 DEVELOPING THE SOLUTION
9 FORESEEING PROBLEM OF RESISTANCE
CHECK
TRIAL IMPLEMENTATION & CHECK
10
PERFORMANCE
11 REGULAR IMPLEMENTATION
ACT
12 FOLLOW UP & REVIEW
TRELLEBORG GROUP
PLAN ACTUAL DELAYED
50
52. Review of Monthly Rejection Trend
Rejection Percentage of Extra bond has been dropped down to Zero (0) percent
Overall Rejection cost on October’12 has been reduced 92.67% than September’ 12
TRELLEBORG GROUP
52
53. Review of Rejection Contribution Analysis
96 100
800 100
91
84
76
600 67 75
57
400 46 50
Before
Q
R
31
y
e
t
j
255
%
m
C
u
e
v
a
t
i
l
200 25
120
92 82 78 66 54 45 30
0 0
0
9
V
A
4
6
0
V
A
0
5
6
0
V
A
1
4
1
2
V
A
5
1
2
V
A
0
4
5
1
V
A
0
0
5
2
V
A
0
4
3
1
V
A
0
9
2
0
V
A
100
95 100
87
77
75
400 66
52
50
37
Q
R
y
e
t
j
200
After
%
m
21
C
u
e
v
a
t
i
l
120 25
92 82 78 66 54 45 30
0 0
0
4
6
0
V
A
0
5
6
0
V
A
1
4
1
2
V
A
1
5
1
2
V
A
0
4
5
1
V
A
0
0
5
2
V
A
0
4
3
1
V
A
0
9
2
0
V
A
TRELLEBORG GROUP
54. Benefits : Tangible
1. Quality Improvement:
Rejection % of Extra bond reduced to 0% from 2.52%
2. Productivity Improvement:
Gross Production / shift has been increased to 4000 nos. to 4364
nos. per shift
3. Cost Saving:
Rejection cost has been reduced to Rs. 1057/- from Rs. 32630/-
4. Customer Concern:
Internal customer is happy
TRELLEBORG GROUP
54
55. Benefits : Intangible
Improved problem solving skills of operators.
Boost up the confidence level.
Improved shop floor employees participation.
Two more Quality Circle team have come up within one month.
Improved Team work
Developed positive attitude towards work and company.
TRELLEBORG GROUP
55
56. Horizontal Deployment
The same fixture modification can be done on AV 2141 outer, AV
2151 outer, AV 2091 outer, AV 1340 outer
AV 2141 AV 1340
AV 2091
AV 2151
TRELLEBORG GROUP
56
57. Next QCC Target
Extra Bond in AV 0640B Inner
TRELLEBORG GROUP
