PowerPoint Presentation

To improve cluster gauge compliance for Minimizing Rework, Rejection, and Line Downtime for X445 FCM from 40% to 5 % by Oct-24 SKHM Warriors, Pune India.

[Audio] The project is indeed a strategic priority, aligned with our organization's goals. Its high impact on quality, cost, and delivery makes it a complex issue that requires careful attention. Multiple possible causes have been identified, but some significant causes remain unknown, and so do their corresponding solutions. This chronic problem has been affecting us for quite some time, and we need to take decisive action to address it. The potential benefits of this project are clear, and we've already measured the current level of the parameter we want to improve. Our scope is well-defined, and we have the right team members working together to achieve our objectives. They're all aware of the processes involved, and management has committed the necessary resources to support our efforts. Finally, we've received approval from our head of department to move forward with this project, and we're confident that we can complete it within six months..

[Audio] Our team consists of dedicated professionals who have come together to achieve a common goal. Mr. Umesh Gunjal, the team leader, guides us through this journey. Mr. Chandrashekhar Jagtap, our champion, ensures that we stay focused on our objective. With the necessary support and resources, Mr. Vedant Kadam, our head sponsor, enables us to work effectively. Furthermore, our in-process champions, including Mr. Sudhir Mali, assist us in overcoming any challenges that may arise during our project..

[Audio] The team was formed on September 6th, 2023, and has been meeting every Monday from 10:00 PM to 10:30 PM at the X445 FCM assembly area. The team has had eight meetings so far, with an attendance rate of 96%. The registration number and date for this project are SKH M/QC/23~24/MFG 04. The plan calls for the actual start date to be September 6th, 2024, with a completion date set for October 31st, 2024. This information is applicable for the quality control story..

[Audio] We need to define the problem, identify its root cause, and develop a plan to address it. The first step is to gather data on the current situation, including the frequency and reasons for non-compliance. This will help us understand the scope of the issue and identify potential areas for improvement. We can use tools such as statistical process control charts to analyze the data and identify trends and patterns. Once we have a clear understanding of the problem, we can start brainstorming potential solutions. We should consider all possible options, including changes to our processes, training for our employees, and investments in new technology. We also need to anticipate any resistance to change and develop strategies to overcome it. After selecting a solution, we'll implement it and monitor its effectiveness through trials. Finally, we'll validate the root cause of the problem and follow up to ensure that the solution is working as intended..

6. STEP 2 SELECTION OF PROBLEM.

[Audio] The assessment of risk is crucial in this project because several potential risks have been identified that could impact our ability to achieve the desired outcome. The chart reveals various defects and issues related to cluster gauge non-compliance, including burn-through, box open eye lash, part damage, cluster gauge not qualify, burr issue, porosity weld shift, and concentricity not okay. These defects can lead to rework, rejection, and line downtime, ultimately affecting our production capacity and quality. Moreover, the internal PPM rate is increasing over time, necessitating immediate action to address these issues. According to our risk assessment, the most critical areas requiring urgent attention are cluster gauge not qualify, burn-through, and box open eye lash. Mitigation strategies must be developed to mitigate these risks and ensure that our production meets the required standards..

[Audio] The activities planned for September and October have been carefully laid out to ensure a structured approach towards identifying and addressing the root cause of the problem. The problem selection activity has already begun, and we are currently analyzing the issue to identify its scope and impact. This will enable us to focus on the most critical areas requiring attention. Once the problem analysis is complete, we will train our team members on the necessary skills and knowledge required to tackle this challenge. Next, we will identify potential causes and validate them through various means. Following this, we will conduct a root cause analysis to pinpoint the exact reason behind the non-compliance. With the root cause identified, we can then generate ideas for improvement and implement them as planned. Throughout this process, we will track our performance and standardize our procedures to ensure sustainability..

9. STEP 3 DEFINE THE PROBLEM.

[Audio] The cluster gauge fails to qualify X445 FCM parts, leading to a surge in rework and rejection. This issue was identified during attribute gauging on the X445 FCM assembly line, where the cluster gauge operation number is involved. The problem began on May 24th and occurs randomly, resulting in a significant impact of 10% rework. To resolve this situation, the production line must be halted temporarily whenever the gauge fails to qualify..

Problem Identification. [image]. [image]. [image].

[Audio] The actual monthly FCM rework hours have been recorded at 184 hours, resulting in a significant impact on our production efficiency. Furthermore, the rejection cost of subframes has reached Rs 15,103, while the line downtime due to rework at the assembly stage amounts to 235 minutes per month. This highlights the need for immediate attention to address these issues. The current FTT rate stands at 87%, indicating room for improvement. By engaging with the cross-functional team, we can deliver a project plan that targets corrective actions to minimize rework, rejection, and line downtime, ultimately achieving our goal of reducing these metrics from 40% to 5%..

[Audio] The monthly FCM rework increases up to 88 hours per month, resulting in line downtime at the assembly stage of up to 235 minutes per month. This also leads to rejection costs of up to 15,103 rupees per month. Furthermore, we can achieve a reduction of up to 87% in FTT in a single month..

[Audio] The process flow diagram illustrates the various stages involved in producing X445 FCM, emphasizing the significance of cluster gauge inspection, manual welding, MIG welding, projection welding, and attribute gauge inspection in guaranteeing the quality of the final product. The suspected occurrence station is depicted, signifying areas where potential problems might emerge. The diagram offers a visual representation of the intricate process, enabling us to comprehend the sequence of events and pinpoint potential obstacles..

[Audio] På dette dias, nummer 15 ud af 40, vil vi fokusere på forbedring af cluster gauge overholdelse for at minimere omarbejde, afvisning og nedetid for X445 FCM fra 40% til 5% inden den 24. oktober. Vi vil se nærmere på de forskellige svejseteknikker, der anvendes i produktionen af X445 FCM. Vi har OP-05B LH og OP-05B RH, som er projekteringssvejsning, og MIG-svejsning på OP-90A LH/RH og OP-90B LH/RH. Der er også OP-100 med MIG-svejsning og OP-25_1 med manuel svejsning. Vi har også OP-50 med MIG-svejsning og OP-50A, som er cluster gauge inspektion, samt OP-45 med MIG-svejsning og OP-15 og OP-20 med MIG-svejsning. Endelig har vi OP-110 A&B med MIG-svejsning og OP-15A1, 15A2 LH/RH og OP-15B LH/RH. Alle disse processer og teknikker har en vigtig rolle i produktionen af X445 FCM, og det er afgørende, at de udføres korrekt for at opnå den ønskede reduktion i cluster gauge overholdelse. Det er vigtigt, at vi alle følger de korrekte procedurer og standarder, da en lille fejl kan have store konsekvenser for det endelige produkt og resultere i omkostningstungt omarbejde, afvisning og nedetid. Vi vil fortsætte med at gennemgå disse processer og sikre, at alle forstår deres rolle og ansvar i at sikre en højere overholdelse af cluster gauge for X445 FCM. Vores mål er at nå 5% overholdelse inden deadline den 24. oktober. Sammen kan vi opnå dette mål og sikre effektiv produktion af X445 FCM. Tak for jeres tid og fortsat godt arbejde..

[Audio] The analysis of the problem involves identifying the root cause of the issue. We need to understand why we have a 40% non-compliance rate in our cluster gauge measurement. Whether it is due to inadequate training, uncalibrated equipment and tools, lack of standard operating procedures, or human error, we must gather data and facts to determine the root cause of this problem. This will enable us to identify the most effective solution to minimize rework, rejection, and line downtime..

[Audio] The CPP'V La, also known as the Control Plan Process Verification Laboratory, has a vital role in guaranteeing the quality of our products. By verifying the control plan, we can detect potential problems and take corrective measures to minimize rework, rejection, and production downtime. This is crucial for reaching our objective of decreasing cluster gauge compliance from 40% to 5% by October 24. With the CPP'V La's assistance, we can ensure that our products conform to the necessary standards, thus lowering the likelihood of defects and enhancing overall product quality..

Team Engagement During Project Review. Discussion on weekly activities Team engagement during project review.

[Audio] The potential causes of the non-compliance of cluster gauge for X445 FCM were identified through various means including interviews, observations, and data analysis. The main causes included inadequate training of production staff, lack of clear guidelines on cluster gauge calibration, insufficient quality control checks during production, and incorrect cluster gauge settings. These causes needed to be addressed to minimize rework, rejection, and line downtime for X445 FCM..

[Audio] The root cause analysis reveals that the non-compliance of cluster gauge is due to various factors including gaps between parts and mylar, manual intervention by operators, unskilled operators, child parts having issues with locating holes and slots, eyelashes positions, and twisting shifts. The man factor also played a crucial role as operators lacked proper training and experience. Measurement tools were inadequate resulting in inaccurate readings. Standard operating procedures were not available for stage-wise checking leading to inconsistencies. Child part trim and form variations, high points, and burrs, sharp edges, and profiles that did not meet specifications were other contributing factors. Finally, tower positions showed tapers at sub-assemblies, and OP-20 subassembly boxes were open indicating further issues. These root causes highlight the need for corrective actions to ensure cluster gauge compliance and minimize rework, rejection, and line downtime..

[Audio] The validation results indicate that multiple causes require attention. Specifically, the gap between the part and mylar was found to be acceptable, but the clamping mylar was missing, which could have posed a problem if left unaddressed. Additionally, the part locating pin was present and correctly positioned in the fixture. However, issues arose with the tower pin, exhibiting taper and shift at the sub-assembly level, and the RLCA box displayed taper at the same level. Moreover, the OP-10 sub-assembly showed twist and shift, whereas the OP-20 sub-assembly had its box open, failing to meet specifications. These findings necessitate further examination and corrective measures to guarantee compliance with specifications and minimize rework, rejection, and downtime..

[Audio] The validation process reveals that several causes contribute to the non-compliance of the cluster gauge. Manual intervention by operators is one cause, where they do not properly check parts and fixtures, leading to hampered production. Lack of adequate specifications in standard operating procedures is another cause, resulting in the absence of specific check points for verifying product quality. The unavailability of snap gauges for stage-wise checking makes it difficult to ensure product quality. Material-related issues, including child part trim/form variations, stamping part eyelashes position, child part burr, sharp edges, and profile, are also problematic. Multiple factors contribute to the non-compliance of the cluster gauge, requiring a comprehensive approach to address these issues and improve overall product quality..

[Audio] The observations reveal that there is a significant issue with the tower position taper at the sub-assembly level. The CMM report indicates that the tower sleeve exhibits a taper or shift during the sub-assembly process, which is noticeable in both the X and Y directions. Measurements show a 1.1 millimeter taper in the X direction and a 0.7 millimeter taper in the Y direction. These findings imply that the tower position is not being maintained accurately, potentially compromising cluster gauge compliance. Further examination is necessary to identify the root cause of this problem and implement corrective measures to reduce rework, rejection, and line downtime..

[Audio] The observations reveal that a gap exists between the upper left-hand panel and the middle panel, indicating that the sub-assembly twist or shift is responsible for non-compliance with cluster gauge specifications. This discovery confirms our initial suspicion that the root cause of the problem originates from the manufacturing process, particularly during the sub-assembly stage. A more thorough examination is necessary to verify this theory and determine potential corrective measures..

[Audio] The observations reveal that the box width exceeds the specified range of 65.6mm to 66.6mm. This discovery confirms that the OP-20 sub assembly box is indeed open. The importance of this finding cannot be overemphasized, as it underscores a crucial problem that must be resolved to guarantee conformity with specifications and reduce rework, rejection, and production downtime..

[Audio] The observations reveal that the box width was found to be oversized as per specification, measuring between 65.6 millimeters and 66.6 millimeters, which is a significant cause of non-compliance with the cluster gauge requirements..

[Audio] The data analysis has revealed some interesting patterns and trends. During peak production hours, the non-compliance rate for cluster gauges on the X445 FCM production line is significantly higher. This suggests that there may be some underlying issues with our quality control processes or equipment maintenance schedules. Certain operators have been consistently reporting higher-than-average defect rates, indicating potential training or skill gaps. Systemic issues with our documentation and record-keeping practices may also be contributing to the overall non-compliance rate. These findings will inform our next steps in addressing this problem and implementing corrective actions..

[Audio] The reason why the sleeve is not inserted properly in the reinforcement at Op- is due to a high point at the sleeve mating trim of the reinforcement, resulting in a gap. This gap causes the Tower position to taper during the assembly process. As a result, we have a non-compliant cluster gauge. We need to investigate further to understand why this is happening. Is it because of a punch and block mismatch at the cam pierce operation at the supplier's end? We need to verify the root cause of this issue..

[Audio] The gap observed between the upper and power panel of the op-20 box is because the op-20 box is open. This is caused by the manual clamping cylinder generating a gap at the op-20 box, which is not working in auto mode..

[Audio] The observations indicate that a gap exists between the side panel and middle panel of the OP-10 sub-assembly due to the fact that it should not twist or shift. Moreover, the middle panel sleeve position was found to be tapered at the sub-assembly, resulting in a gap between the sleeve and the resting mylar in the fixture. This unacceptable gap necessitates prompt attention to guarantee proper assembly and reduce rework, rejection, and line downtime..

[Audio] The development of solutions involves identifying potential solutions to address the root cause of the problem. We will work closely with the team to brainstorm and identify potential solutions. These solutions will then be evaluated based on their feasibility, cost, and potential impact. The best solution will be selected and implemented..

[Audio] The probable cause of the non-compliance of the cluster gauge was due to the tower position taper being high. Mr. Yogesh Chafle removed this issue in the child part on 15th October 2024, as evidenced by the supplier one pager. Moreover, the punch was replaced with a new one, and the manual cylinder was replaced by an auto-cylinder. Additionally, the snap gauge was implemented for stage-wise checking, and the middle panel sleeve position was corrected in the Z-direction. These actions aimed to reduce rework, rejection, and line downtime for X445 FCM..

[Audio] Anticipating potential resistance to our proposed changes is crucial. Various sources may contribute to this resistance, including team members who might feel threatened by new processes, stakeholders who may have vested interests in maintaining the status quo, or external factors like regulatory bodies imposing additional requirements. By foreseeing these probable resistances, we can develop strategies to mitigate them and ensure a smoother transition to the new system..

[Audio] The root cause analysis identified several factors contributing to the non-compliance of cluster gauge, including machine/tool issues, method problems, environmental factors, and material defects. Key reasons included manual intervention by operators, gaps between parts and mylar, unskilled operators, child part locating hole and slot shifts, and the absence/partial presence of part locating pins. Additionally, a lack of standard operating procedures, inadequate training, and poor measurement techniques also played a role. To address these root causes, we will implement measures such as upgrading tooling, improving maintenance practices, enhancing production processes, and providing training to inspectors..

[Audio] As we move forward with our efforts to improve cluster gauge compliance for minimizing rework, rejection, and line downtime for X445 FCM, we have reached STEP-10: Trial Implementation & Check Performance. The purpose of this step is to test the effectiveness of our proposed solutions and to measure the performance against our target of reducing the mentioned issues from 40% to 5% by October 24. During this trial phase, we will carefully implement the proposed changes and closely monitor the results. This will give us an opportunity to identify any potential roadblocks or challenges that may arise and address them accordingly. We understand that change can be difficult and may not always produce immediate results, but we must stay committed to this process in order to achieve our goal. So, it is important to stay engaged and provide feedback as we work towards improving our cluster gauge compliance. Once the trial period is complete, we will evaluate the performance and make necessary adjustments to ensure we are on track to meet our target. This will require data analysis and collaboration between our team members to identify areas of improvement. Our ultimate goal is to minimize rework, rejection, and line downtime for X445 FCM. So, let us approach this step with determination and a positive mindset, knowing that each small step we take brings us closer to our desired outcome..

[Audio] The sustenance plan outlines the steps taken to ensure the control plan is revised and updated regularly. The addition of flange inner dimension in OP-50 and OP-80 ensures that all necessary parameters are considered. The PFMEA is also updated regularly to reflect changes and improvements. The first piece inspection report is added to verify the quality of products during production, and inspectors receive training to ensure they can perform their duties effectively. This plan helps maintain consistency and accuracy throughout the manufacturing process..

STEP 11 Results.

[Audio] We learned that verifying inner and outer part stack-up tolerance is crucial in maintaining and eliminating gap issues. This experience will guide us in future projects, where we'll need to verify stack-up drawing tolerance to prevent similar problems. Moreover, it's essential to conduct inner and outer parts fitment verification during production run trials. We've successfully applied horizontal deployment to another comparable project..

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[Audio] Our goal is to improve cluster gauge compliance for X445 FCM. We aim to minimize rework, rejection, and line downtime from 40% to 5% by October 24. However, we cannot achieve this goal alone. Your cooperation and feedback are crucial in helping us meet your expectations. We value your opinions and want to ensure that we are meeting your needs. As we work towards this target, we ask for your continued support and collaboration. Your feedback and comments are greatly appreciated..