project ppt. (1)

SIX MONTHS ACTIVITIES AT GREAVES COTTON LTD. PUNE

ASSET VERIFICATION

1. STANDARD PLASTIC PVT. LTD.

2. LUBRICARE PVT. LTD.

3. TATA TOYO (SANDEEP ENGINEERS.PVT. LTD.)

4. KALYANI TECHNOFORGE

5. KALYANI FORGING PVT. LTD.

6. JAGDAMBA AUTO COMPONENT PVT. LTD.

LIST OF SUPPLIERS VISITED IN PUNE 1. GANESH FOUNDARY2. YASHRAJ ALLOY INDUSTRIES PVT. LTD. MARUNJI, PUNE3. SIDHIVINAYAK GENSET PVT. LTD.4. LAKSHMI ENGINEERING WORKS5. SANTOSH ENGINEERING WORKS6. MATCHWELL ENGINEERING PVT. LTD.7. STANDARD PLASTIC PVT. LTD.8. LUBRICARE PVT. LTD.9. TATA TOYO (SANDEEP ENGINEERS.PVT. LTD.)10. YAWLKAR INDUSTRIES11. POLYHOSE PVT. LTD.12. KBK INDUSTRIES13. RIVOLTECH AUTO COMPONENT PVT. LTD.14. KALYANI TECHNOFORGE15. KALYANI FORGING PVT. LTD.16. JAGDAMBA AUTO COMPONENT PVT. LTD.17. AMBIKA ENGINEERING18. KELVION INDIA PVT. LTD.

PRODUCTION PART APPROVAL PROCESS (PPAP) VERIFICATION

1. YASHRAJ ALLOY INDUSTRIES PVT. LTD.

2. SIDHIVINAYAK GENSET PVT. LTD.

FOLLOW UP AUDITS



3. POLYHOSE PVT. LTD.

4. AMBIKA ENGINEERING

PROCESS AUDIT REGARDING CUSTOMER COMPLAINTS



3. AMBIKA ENGINEERING

QUALITY IMPROVEMENT RELATED MEETINGS

1. TATA CUMMINS (TURBOCHARGER)

2. UNITED RUBBER PVT. LTD. MUMBAI ( HOSE BURST)

3. BOSCH PVT. LTD. BANGALORE ( FUEL INJECTION PUMP)

4. SANJEEV AUTOS ( CRANKSHAFT GEAR)

SUPPLIER ASSESMENT AUDIT

1. KELVION INDIA PVT. LTD.

PROJECTS

1. Quality improvement

2. PPAP verification

3. Process audit regarding customer complaints

4. Reduce PPM level

5. Reassembly of hydraulic unit of CNC machine in AEB

QUALITY IMPROVEMENT

At GCL , from last few days we are facing a leakage problem from turbo oil drain pipe in testing. It is also a customer complaint which is also highlighted by our service team. Hence I had taken this up as a major

project here.

PROBLEM : LEAKAGE

• Leakage from ferrule & nut• Leakage from hose • Leakage from flange

• TURBO OIL DRAIN PIPE

• The lubricating oil flows into the turbocharger at a pressure of approximately 4 bar. The oil drain pipe should be returned into the crankcase above the engine oil level. Any obstruction in the oil drain pipe will result in back pressure in the bearing system

INTRODUCTION

• The main function of turbo oil drain pipe is only drain the oil from turbocharger to crank case.

• The figure shows the functional view of turbo oil drain pipe

FUNCTION OF TURBO OIL DRAIN PIPE

MATING COMPONENTS OF TURBO OIL DRAIN PIPE

• Turbo bend

• Bend between manifold & turbo

• Adaptor 30*30

• Ferrule & nut

• Crank case

• Lifting bracket

• 100% checking on fixture

• Pipe is checked on fixture before crimping & marking a position and then crimping done on pipe

• After crimping it is again checked on fixture

• When pipe does not fit on fixture, it is rejected at supplier end itself.

• Fixture is checked and given by GCL

• Polyhose Pvt. Ltd. – in polyhose meet with Mr. Amol (quality).

• Process for making pipe

• Cutting hose

• Crimping process

• Checking on fixture

• 100% inspection

• dispatch

TURBO OIL DRAIN PIPE

Process audit related to turbo oil drain pipe

Observations

TURBO OIL DRAIN PIPE IS OK AT SUPPLIER END BUT STILL THERE

LEAKAGE FROM PIPE AT GCL. WHY ?

BELOW FIGURES SHOWS THE PIPES OK ON FIXTURE PRESENT AT SUPPLIER END

ANALYSIS OF TURBO OIL DRAIN PIPE

• Checking all mating components of turbo oil drain pipe at GCL

FERRULE & NUT

Ferrule cone angle required 24°

Observed 24°. This is verified on contour machine in GID the evidence for the same is enclosed in the project file.

NUT HIEGHT IS 17 MM ON DRAWINGWhen the nut height is 17mm only 2~3 threads of the adaptor are covered.

When the height is made 20mm , it cover all the threads.

THIS REASON FOUND FOR LEAKAGE FROM NUT & FERRULE

• Ferrule angle 24° ok

• Adaptor angle 24° ok

• Nut height is less 17 mm it is less for proper fitting.

• observation : nut, ferrule & adaptor buy from different-different suppliers & R/D design not ok on nut.

• Suggestion: ferrule & adaptor must buy from one supplier.

R&D DESIGN CHANGE UNDER IMPLEMENTATION

• Finally R&D dept. focused on the subject issue & ECN has been implemented on the nut.

• The new design implemented by the ECN is awaited in the next lot.

• Adaptor is mating with turbo bend & turbo oil drain pipe.

• Checking adaptor cone angle on CMM machine.

• CMM report attach in project file.

• Required angle : 24 degree

• Observed angle : 24 degree

• Result : angle is ok.

ADAPTOR CONE ANGLE 24 DEGREE REQUIRED

FLANGE WIDTH UNDERSIZE

26mm

Observed 26 mmAs per drawing 31mm

CORRECTIVE ACTION TAKEN BY SUPPLIER

These gauge is special making for eliminate flange related issue.Flange is pass through this two jaws 100% inspection.

When flange not pass through this jaws then rejected on supplier end.

TURBO BEND

Dimensional view of turbo bend

CHECKING DIMENSIONS IN GID

Pointer set on zero on height gauge

Flange to threading hole centre

Observed 79 mm

DIMENSIONS VARIATION

• In turbo pipe dimension required 75 mm

Observed 79 mm

• 3~4 mm dimensional variation in turbo bend height

• report attached in project file

BEND BETWEEN MANIFOD & TURBOCHARGER

Dimensional view Check dimns. On height gauge

DIMENSIONS VARIATIONS

• 1. From mounting hole to threading centre distance required 47.5 mm.

OBSERVED: 45.83 mm

• 2. Face to threading centre distance required 85 mm

OBSERVED: 83.5 mm

• 3. Total height required 120 mm.

OBSERVED: 120 mm

• 4. Hole to hole distance required 70 mm

OBSERVED: 70 mm

RESULT: 2 mm variation in mounting hole to thread centre.

CRANKCASE

Flange side turbo pipe mount on crank case that’s why check the dimensions of crankcase threading hole distance from finish surface in Rivoltech auto component pvt. ltd.

RESULT: Crank case turbo oil drain pipe flange side holes are ok straight in line.CMM report attached in project file.

OBSERVATION• 3~4 MM VARIATION IN TURBO BEND HEIGHT

• 2 MM VARIATION IN MOUNTING HOLE TO THREAD CENTRE

• CMM REPORT OK NO VARIATION ON CENTRE LINE OF CRANK CASE

• ADAPTOR CONE ANGLE 24 DEGREE OK

• FERRULE ANGLE 24 DEGREE OK

• LIFTING BRACKET 1 MM VARIATION ON BOTH CLAMPING SIDES

CONCLUSION

• WRONG STANDARD OPERATING PROCEDURE (SOP/WI).

• TURBO BEND HEIGHT VARIATIONS.

• DIMENSION VARIATION.

• COMMUNICATION GAP.

• UNSKILED OPERATOR.

CORRECTIVE ACTION

• CHANGE IN SOP/WI

• IMPLEMENTATION OF TURBO BEND AT SUPPLIER END

• IMPLEMENTATION OF CONTROLLING DIMENSIONAL VARIATION

• FOLLOW UP OF SUPPLIERS

LIFTING BRACKET SOP/WI CHANGED

SOP/WI before observation

SOP/WI FINALLY CHANGED

SOP/WI after observation

TURBO OIL DRAIN PIPE SOP/WI CHANGE

Turbo drain pipe SOP/WI before observation

SOP/WI FINALLY CHANGED

Turbo drain pipe SOP/WI after observation

BEFORE AFTER

Bend in hose (leakage in testing) SOP/WI wrong Reduce bend in hose trail on 5 engines. SOP/WI change in D assembly in GCL,PUNE

KAIZEN SHEET

P ↑ Q ↑ C D S M ↑

KAIZEN THEME : To improve quality by eliminate or reduce leakage from turbo oil drain pipe & sop change

Kaizen no.: 001/IEB

Supplier Name : polyhose Pvt. Ltd. Ref- trail in assembly on five enginesPart No./ Part Name : turbo oil drain pipe Kaizen Date : 10//04/2016

BU : IEB FEB IEB/APB

SUGGESTIONS• THIER SHOULD BE IMPROVE IN COMMUNICATION GAP

B/W R/D DEPT. & SUPPLIER & INSIDE GCL.

• THE DESIGN OF TURBO OIL DRAIN PIPE MUST BE CHANGE.

• ELIMINATE TURBO BEND & ADAPTOR , MOUNT DIRECT PIPE FROM TURBOCHARGER TO CRANK CASE.

• PLEASE ALWAYS DO TEAM WORK.

• TRAINING MUST BE GIVEN TO NEW OPERATOR.

• IN ASSEMBLY ,THEIR SHOULD BE DISPLAY FIELDS COMPLAINTS OR CUSTOMER COMPLAINTS ON ASSEMBLY.

THANK YOU

project ppt. (1)

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