2. D M A I C
Define Measure Analyze Improve ControlDefine
D Measure
M Analyze
A Improve
I Control
C

3. D M A I C
Define Measure Analyze Improve ControlDefine
D

4. D M A I C
Define Measure Analyze Improve Control
NISSAN booster assy line
Front shell
shear riveting
Front shell
Spring pri-assy
Front shell &
diaphragm assy
Collar height
setting
Booster assyBrakes “OFF”
testing
Brakes “ON”
testing
mBA actuation
test
Booster
crimping
Output rod
height setting
Booster &
TMC coupling
Booster &
TMC coupling
Booster &
TMC Duplex test
Clevis height
setting
Final Inspection
Process flow
Define
D

5. D M A I C
Define Measure Analyze Improve Control
Rework
Inspection
Warranty
Rejects
Lost sales
Latedelivery
Engineeringchangeorders
Longcycletimes
Expeditingcosts
Excess inventory
HiddenCosts
VisibleCosts
Lost CustomerLoyalty
MoreSet-ups
Timevalueof money
WorkingCapitalallocations
ExcessiveMaterial
Orders/Planning
Recode
(less obvious)
COPQ- Iceberg Measure
M

6. D M A I C
Define Measure Analyze Improve Control
Spring
noise
Spring
rubbing
Improper
seating
Improper assy
WHY WHY analysis
Analyze
A

7. D M A I C
Define Measure Analyze Improve Control
Improper assy of spring
MachineMaterial
Operator
Environment
Training
Method
Spring
dimension
Spring Bend
Improper clampclamp device
Prong dimension
Pressure
variation
Analyze
AAnalyze Phase

8. D M A I C
Define Measure Analyze Improve Control
NISSAN booster assy line
Front shell
shear riveting
Front shell
Spring pri-assy
Front shell &
diaphragm assy
Collar height
setting
Booster assy
Process flow
PHOTO
PHOTO
Analyze
A

9. D M A I C
Define Measure Analyze Improve Control
Any abnormality in assy station ?
 Spring NOT releasing after pressing PB
 Spring released earlier before pressing PB
 Spring adjusted manually by screw driver for proper seating of
spring in retainer
Analyze
AAnalyze Phase

10. D M A I C
Define Measure Analyze Improve Control
Spring adjusting manually
by screw driver for proper
seating in valve body
Spring improper seating
Analyze
AAnalyze Phase

11. D M A I C
Define Measure Analyze Improve Control
Clamping Prong dimensions verified
Spring Concentricity verified
Observations
Why 100% samples is not getting rejected ?
Why 100% samples is not getting OK?
Analyze
AAnalyze Phase

12. D M A I C
Define Measure Analyze Improve Control
Spring pre-assy fixture are identified and spring seating verified after assy.
Analyze
AAnalyze Phase

13. D M A I C
Define Measure Analyze Improve Control
Proper seating of spring in valve body observed in pre-assy fixture -3.
What's the mismatch between Fixture-3 & Fixture -1,2,4 ?
Analyze
AAnalyze Phase

14. D M A I C
Define Measure Analyze Improve Control
Prongs
Front shell
Fixture -1,2,4 Fixture -3
FIXTURE MODEL
Fixture bottom
Spacer
GAP
Analyze
AAnalyze Phase

15. D M A I C
Define Measure Analyze Improve Control
θ
GAP
Front shell
Spring
Prongs
Spring locator no. 1, 2, 4
Spring
deformed
Analyze
AAnalyze Phase

16. D M A I C
Define Measure Analyze Improve ControlImprove
I
Recommendations for improving the process:
• All 4 Fixtures to be replaced identically like fixture-3
Implement the above recommendations and run additional samples to verify results.
Improve Phase

17. D M A I C
Define Measure Analyze Improve ControlControl
C
Recommended controls :
• Implement color coding for NISSAN fixture.
Control Phase