Shock Absorber

Quality Maintenance

Magneti Marelli Motherson Shock Absorbers India

Quality ControlQuality Maintenance – ACME PU1310

Project Leader – Sachin Dhawale

World Class Manufacturing

Shock Absorber

Processes:

Un

itCe

llPr

oces

sUn

it Ce

ll Pr

oces

s

1 2 3 4

Nissan, GM, TML, Jamna All Models Front Strut Groove Dia U/S (A) 70Nissan, FIAT All Models Gas Spring Groove Dia O/S (A) 70FIAT Europe Fam A & B Rear Shocks Step Dia.Ø 7.92 O/S( (A) 40FIAT Europe Fam A & B Rear Shocks Step Dia. Ø 7.92 U/S (A) 40FIAT Europe Fam A & B Rear Shocks Binder 30Punto RR, All Models Front Strut Upper Welding Blow hole 18

Criti

calit

y Ind

ex:

Custo

mer

Mod

el

Appl

icatio

n

Occu

ranc

e

Defects

4th QA Matrix 2014

Period SEP 2014 to DEC 2014 Plant - MMSA, Pune I1301

Incoming

Material

1301 Incoming Material

4M

Proc

ess

Weig

htag

e (H,

M,L)

2

4M - Machine

Project – ACME Improvement

Investigate current condition

Step 2 Step 3 Step 4 Step 5 Step 6 Step 7Step 1

Shock Absorber 3

4M - Machine

Project – ACME Improvement

Investigate current condition

Step 2 Step 3 Step 4 Step 5 Step 6 Step 7Step 1

Shock Absorber

Quality Maintenance

Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2

Investigating Current Condition

10.710.610.510.410.310.2

LSL USL

LSL 10.3Target *USL 10.7Sample Mean 10.473Sample N 50StDev(Within) 0.119712StDev(Overall) 0.112418

Process Data

Cp 0.56CPL 0.48CPU 0.63Cpk 0.48

Pp 0.59PPL 0.51PPU 0.67Ppk 0.51Cpm *

Overall Capability

Potential (Within) Capability

PPM < LSL 20000.00PPM > USL 20000.00PPM Total 40000.00

Observed PerformancePPM < LSL 74210.28PPM > USL 28965.82PPM Total 103176.10

Exp. Within PerformancePPM < LSL 61914.04PPM > USL 21730.43PPM Total 83644.47

Exp. Overall Performance

WithinOverall

Process Capability of Piston Groove Dia

Quality Maintenance

Shock Absorber

Quality Maintenance

Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2

Investigating Current Condition

7.9207.9047.8887.872

LSL USL

LSL 7.87Target *USL 7.92Sample Mean 7.89592Sample N 50StDev(Within) 0.0136475StDev(Overall) 0.0161496

Process Data

Cp 0.61CPL 0.63CPU 0.59Cpk 0.59

Pp 0.52PPL 0.53PPU 0.50Ppk 0.50Cpm *

Overall Capability

Potential (Within) Capability

PPM < LSL 80000.00PPM > USL 40000.00PPM Total 120000.00

Observed PerformancePPM < LSL 28765.60PPM > USL 38829.84PPM Total 67595.44

Exp. Within PerformancePPM < LSL 54247.71PPM > USL 67973.14PPM Total 122220.85

Exp. Overall Performance

WithinOverall

Process Capability of Piston End Dia

Quality Maintenance

Shock Absorber

Quality Maintenance

Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2

Restoration of Equipment to proper working condition for known causes

Groove stopper bolt changed, to avoid groove dia (Ø 10.3 ±0.2) oversize & undersize problems

To avoid fall of burr on bolt, oil pipe fitted & oil sprinkles starts

All controls & its light restored Feeding roller changed

Shock Absorber

Quality Maintenance

Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2

Restoration of Equipment to proper working condition for known causes

Missing bolts fitted Main part counter restored

For better tool life monitoring part counter fitted for each tool

Shock Absorber

Quality Maintenance

Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2

Restoration of Equipment to proper working condition for known causes

Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2

Restoration of Equipment to proper working condition for known causes

Month wise defect PPM

1. Light fitted inside of ACME Machine

2. OPL For Chamfer Damage

3. OPL For Piston End Dia

4. OPL For uneven Chamfer

5. Q Spot makes all required gauges available for

machine

6. Cpk of Piston Groove Dia = 2.15

7. Cpk of Piston End Dia = 2.19

Shock Absorber

Quality Maintenance

Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2

Restoration of Equipment to proper working condition for known causes

Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2

Restoration of Equipment to proper working condition for known causes

Shock Absorber

Quality Maintenance

Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2

Restoration of Equipment to proper working condition for known causes

Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2

Restoration of Equipment to proper working condition for known causes

CHECK

RESTORATION

OK

Shock Absorber

Quality Maintenance

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Investigate Current ConditionsClarify the relationship among

Quality characteristics, equipment and operation

method

Restoration of equipment to proper working conditions for the known causes.. Investigation of 4M Conditions, table of the countermeasures against the defects

Factor analysis of the unknown causes.. Processing Point Analysis (PPA)

Reducing and Eliminating all possible causes of chronic losses

Restoration of equipment based on PPA.. Checking the result of PPA

Establishment of proper conditions for zero defectEstablishment of the inspection standard sheet

by taking proper inspection items into consideration

Maintenance of proper conditions for zero defectCarrying daily inspection and schedule inspection into effect based on the inspection standard sheet

.. QM Matrix

Improvement of Maintenance method of the conditions for zero defectEfficient time-saving checking of the optimal conditions.. Trend Charts Etc.,

OKNOK

CHECK

Shock Absorber

Quality Maintenance

Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2

Establishment of Proper Conditions of 0 Defect

Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2

Establishment of Proper Conditions of 0 Defect

QCAM

EEM

X Matrix

As we observed towards main contributor for defect generation is slider

Q Componen

t

Shock Absorber 13

4M - Machine

Project – ACME Improvement

Maintenance of proper condition for zero defect

Step 2 Step 3 Step 4 Step 5 Step 6 Step 7Step 1

S AF

L C S

D a te : 07/01/2014

A u th o r: K u m b h a r

O n e P o in t L esso n (O P L )

P lan t: M M M S AI, R S A C e n te r /U n it: R S A D e p artme n t: P ro d u ctio n Zo n e /E T U :P isto n R o d

N O T O KN ot ok pos ition o f o il p ipe , w h ich flow gon ing tow ards

o ther d irec tion o f too l

O KO K pos ition o f o il p ipe ,

w h ich flow gon ing tow ards too l

P M

O th e r

Are a/T e am: M an u factu r in g S tatio n : AC M E G in d le y M o d e l/P ro d u ct All O th e r:

P il la rC D F I A M W O Q C S o u rce : O P L N°:

M 13_00943EEM EP M P D EN EN V

T itle : W e a r in g o f p ro te c tio n g lo v e s

NO T O K O K

S AFLCS

Da te : 07/01/2014

Author: Kum bha rT itle : We a r in g o f p ro te c tio n g lo v e s

NO T O K O K

N O T O KN o w asher c lip to the a ir pressure p ipe

O KW asher c lip to the a ir pressure p ipe

Q C S ource : O P L N°: M 13_00943EEM EP M P D EN ENV O the r

P illa rCD FI AM W O P M

O n e P o in t L esso n (O P L )

P lant: M M M S AI, R S A C e nte r/U n it: R S A D e partme nt: P roduction Zone /E T U :P iston R od Are a/T e am: M anufacturing S tation: AC M E G ind le y M ode l/P roduct All O the r:

OPL

Updation: “Q’’ Component slider Lubrication oil & Cutting oil Insert (Tool)

AM Calendar

QCAM

PM

EEM

Shock Absorber

Quality Maintenance

Parameters

Reference (value)

Tollerance

Measuring Tool

Frequency

Responsibility

Standard Document

Q POINT

HML

Part Counter Reflecto meter

Fo

r F

am

A 1

000

rod

s

Fo

r F

am

B 6

00

rod

s

5-7

%

Co

nta

min

ati

on

Wh

eel

Bala

ncin

g

Ali

gn

men

t o

f

un

load

ing

co

nveyo

r

Ro

d p

ass

thro

ug

h c

en

ter

Dre

ssin

g

Fre

qu

en

cy

Oil

Level

To

ol

Lif

e

To

ol

Lif

e

To

ol

Lif

e

± 200 rods - - - -100m

g /

1000lt

r

0.7

mic

ron

max

Electronic Balance

Measuring Visualy

Daily Daily Daily Daily Daily

Gri

nd

ing

Wh

eel

Co

ole

nt

Co

ole

nt

Gri

nd

ing

Wh

eel

Un

load

ing

Co

nveyo

r

Cin

cin

ati

Grindin

g

Cin

cin

ati

Grindin

g

Cin

cin

ati

Grindin

g

Cin

cin

ati

Grindin

g

Sw

anson

Group Machine

OperatorOperator Operator Chemical Lab

Millipore Test

Component

Standard

Control PlanProcess Control

SheetControl Plan

Operator

√

-Machine Start up

Checklist

100 % Visual Inspection

100 % Visual Inspection

100 % Visual Inspection

100 % Visual Inspection

Check

Impact√ √ √

100 % Visual Inspection

√ √ √

QM-Matrix

√

AC

ME

Grindle

y

AC

ME

Grindle

y

AC

ME

Grindle

y

AC

ME

Grindle

y

AC

ME

Grindle

y

Gro

ovin

g

To

ol

Ro

ug

h T

oo

l

Sem

ifin

ish

To

ol

Fin

ish

To

ol

Part

ing

To

ol

Part Counter Part Counter Part Counter

To

ol

Lif

e

To

ol

Lif

e

3000

6000

2800

7500

3000

Operator Operator Operator

- - - - -

Part Counter Part Counter

100 % Visual Inspection

100 % Visual Inspection

100 % Visual Inspection

Daily Daily Daily Daily Daily

Operator Operator

√

100 % Visual Inspection

100 % Visual Inspection

√

QM Matrix

Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2

Establishment of Proper Conditions of 0 Defect

Step 3 Step 4 Step 5 Step 6 Step 7Step 1 Step 2

Establishment of Proper Conditions of 0 Defect

Shock Absorber 15

4M - Machine

A) The settings are defined and shared. (1pt)

B) A method to check the settings is defined. (3pt)

C) The settings are easy to see without special access or tools.(5pt)

A) Difficult to adjust/set.(1pt)

B) Easy to adjust/set.(3pt)

C) Adjustment is automatic.(5pt)

A) During the normal production (1pt)

B) Only at set up / start (3pt)

C) Exceptionally (5pt)

A) Low probability of seeing it. (1pt)

B) The periodic inspection system is able to detect the variation. (3pt)

C) Continuous monitoring ensuring immediate alert. (5pt)

A) Difficult, requiring specialized technical skills and high downtime.(1pt)

B) Easy, once a person is qualified (3pt)

C) Automatic adjustment (closed loop). (5pt)

5 Questions

for 0 Defects

Are the equipment settings varying outside the specification range?

5Is it easy to bring the equipment settings back into specification?

1 Are the settings defined?

4 Is the equipment variation detectable?

2Is the machine easy to adjust to return to specified range?

3

Parameters

Reference (value)

Tollerance

Measuring Tool

Frequency

Responsibility

Standard Document

Q POINT

H

M

L

Before After Before After Before After Before After Before After Before After

A) The settings are defined and shared. (1pt) 1 1 1 1 1 1

B) A method to check the settings is defined. (3pt)

C) The settings are easy to see without special access or tools.(5pt)

5 5 5 5 5 5

A) Difficult to adjust/set.(1pt) 1 1 1 1 1 1

B) Easy to adjust/set.(3pt) 3 3 3 3 3 3

C) Adjustment is automatic.(5pt)

A) During the normal production (1pt) 1 1 1 1 1 1

B) Only at set up / start (3pt)

C) Exceptionally (5pt) 5 5 5 5 5 5

A) Low probability of seeing it. (1pt)

B) The periodic inspection system is able to detect the variation. (3pt)

3 3 3 3 3 3

C) Continuous monitoring ensuring immediate alert. (5pt)

5 5 5 5 5 5

A) Difficult, requiring specialized technical skills and high downtime.(1pt)

B) Easy, once a person is qualified (3pt) 3 3 3 3 3 3

C) Automatic adjustment (closed loop). (5pt) 5 5 5 5 5 5

Total 9 23 9 23 9 23 9 23 9 23 9 23

% Q-Factor per Parameter 36.0% 92.0% 36.0% 92.0% 36.0% 92.0% 36.0% 92.0% 36.0% 92.0% 36.0% 92.0%

Daily

Operator

100 % Visual Inspection

√

ACM

E G

rindl

eyPa

rting

Too

lTo

ol L

ife30

00

-

Part Counter

Operator Operator

100 % Visual Inspection 100 % Visual Inspection

- -

Part Counter Part Counter

Daily Daily

ACM

E G

rindl

ey

ACM

E G

rindl

ey

Sem

ifini

sh

Tool

Fini

sh T

ool

Tool

Life

Tool

Life

2800

7500

√

√ √ √

Impact

√

100 % Visual Inspection 100 % Visual Inspection 100 % Visual Inspection

4 Is the equipment variation detectable?

2Is the machine easy to adjust to return to specified range?

3

5Is it easy to bring the equipment settings back into specification?

QM-Matrix

Group Machine

Component

Standard

Check

1 Are the settings defined?

Are the equipment settings varying outside the specification range?

ACM

E G

rindl

ey

ACM

E G

rindl

ey

ACM

E G

rindl

ey

Gro

ovin

g To

ol

Roug

h To

ol

Parti

ng T

ool

Tool

Life

Tool

Life

Tool

Life

3000

6000

3000

- - -

Part Counter Part Counter

Daily Daily

Part Counter

Operator

Daily

5 Questions

for 0 Defects

Operator Operator

Parameters

Reference (value)

Tollerance

Measuring Tool

Frequency

Responsibility

Standard Document

Q POINT

H

M

L

Before After Before After Before After Before After Before After Before After

A) The settings are defined and shared. (1pt) 1 1 1 1 1 1

B) A method to check the settings is defined. (3pt)

C) The settings are easy to see without special access or tools.(5pt)

5 5 5 5 5 5

A) Difficult to adjust/set.(1pt) 1 1 1 1 1 1

B) Easy to adjust/set.(3pt) 3 3 3 3 3 3

C) Adjustment is automatic.(5pt)

A) During the normal production (1pt) 1 1 1 1 1 1

B) Only at set up / start (3pt)

C) Exceptionally (5pt) 5 5 5 5 5 5

A) Low probability of seeing it. (1pt)

B) The periodic inspection system is able to detect the variation. (3pt)

3 3 3 3 3 3

C) Continuous monitoring ensuring immediate alert. (5pt)

5 5 5 5 5 5

A) Difficult, requiring specialized technical skills and high downtime.(1pt)

B) Easy, once a person is qualified (3pt) 3 3 3 3 3 3

C) Automatic adjustment (closed loop). (5pt) 5 5 5 5 5 5 Before After

Total 9 23 9 23 9 23 9 23 9 23 9 23 54 138

% Q-Factor per Parameter 36.0% 92.0% 36.0% 92.0% 36.0% 92.0% 36.0% 92.0% 36.0% 92.0% 36.0% 92.0% 36.0% 92.0%

Daily

Operator

100 % Visual Inspection

√

ACM

E G

rindl

eyPa

rting

Too

lTo

ol L

ife30

00

-

Part Counter

Operator Operator

100 % Visual Inspection 100 % Visual Inspection

- -

Part Counter Part Counter

Daily Daily

ACM

E G

rindl

ey

ACM

E G

rindl

ey

Sem

ifini

sh

Tool

Fini

sh T

ool

Tool

Life

Tool

Life

2800

7500

Total Machine Q-Factor

√

√ √ √

Impact

√

100 % Visual Inspection 100 % Visual Inspection 100 % Visual Inspection

4 Is the equipment variation detectable?

2Is the machine easy to adjust to return to specified range?

3

5Is it easy to bring the equipment settings back into specification?

QM-Matrix

Group Machine

Component

Standard

Check

1 Are the settings defined?

Are the equipment settings varying outside the specification range?

ACM

E G

rindl

ey

ACM

E G

rindl

ey

ACM

E G

rindl

ey

Gro

ovin

g To

ol

Roug

h To

ol

Parti

ng T

ool

Tool

Life

Tool

Life

Tool

Life N° of

parameters

3000

6000

3000 6

- - -

Part Counter Part Counter

Daily Daily

Part Counter

Operator

Daily

5 Questions

for 0 Defects

Operator Operator

5 Question for Zero defect

QCAM

PM

EEM

Project – ACME Improvement

Improvement of Maintenance methods of conditions for 0 Defect

Step 2 Step 3 Step 4 Step 5 Step 6 Step 7Step 1

B/C 5.6

Shock Absorber 16

4M - Machine

Project – ACME Improvement

Improvement of Maintenance methods of conditions for 0 Defect

Step 2 Step 3 Step 4 Step 5 Step 6 Step 7Step 1

X Matrix

QM Matrix

AM Activities

S AF

L C S

D a te : 07/01/2014

A u th o r: K u m b h a r

O n e P o in t L esso n (O P L )

P lan t: M M M S AI, R S A C e n te r /U n it: R S A D e p artme n t: P ro d u ctio n Zo n e /E T U :P isto n R o d

N O T O KN ot ok pos ition o f o il p ipe , w h ich flow gon ing tow ards

o ther d irec tion o f too l

O KO K pos ition o f o il p ipe ,

w h ich flow gon ing tow ards too l

P M

O th e r

Are a/T e am: M an u factu r in g S tatio n : AC M E G in d le y M o d e l/P ro d u ct All O th e r:

P il la rC D F I A M W O Q C S o u rce : O P L N°:

M 13_00943EEM EP M P D EN EN V

T itle : W e a r in g o f p ro te c tio n g lo v e s

NO T O K O K

S AFLCS

Da te : 07/01/2014

Author: Kum bha rT itle : We a r in g o f p ro te c tio n g lo v e s

NO T O K O K

N O T O KN o w asher c lip to the a ir pressure p ipe

O KW asher c lip to the a ir pressure p ipe

Q C S ource : O P L N°: M 13_00943EEM EP M P D EN ENV O the r

P illa rCD FI AM W O P M

O n e P o in t L esso n (O P L )

P lant: M M M S AI, R S A C e nte r/U n it: R S A D e partme nt: P roduction Zone /E T U :P iston R od Are a/T e am: M anufacturing S tation: AC M E G ind le y M ode l/P roduct All O the r:

OPL

ISSUER /DEPARTMENT

DATA

X

X X

YES NO SIGN

NAMESTANDARDIZATION

EXTENSION OF STANDARDIZATION

SPECIFICATIONS

0.5% TO 1.0% CUT MARK REJECTION

PERIOD INDICATORS OBSERVATION PERIOD INDICATORS OBSERVATION

4 MONTHS % REJECTION 10% TO 15% CUT MARK REJECTION 3 MONTHS % REJECTION

Proper size groove slider bolt

CONSTRUCTION VERIFICATION OPERATIONAL FEEDBACK

HISTORY RESULTS

XENVIRONMENT ERGONOMICS

PROBLEM SOLUTION

PURPOSE OF MODIFICATION IMPROVING MTBF / MTTR AND GERD

PHASE OF CREATION

PLANNING CHECKLIST INSTALLATION VERIFICATION

IMPACT

RELIABILITY MAINTENANCE PRELIMINARY DESIGN VERIFICATION FUNCTIONAL VERIFICATION

QUALITY COST FINAL PROJECT VERIFICATION FINAL CHECK

OPERABILITY SAFETY

DESCRIPTION

Piston Rod ACME Grindley

05-2014PRODUCTIONPROCESS

UPPER MOUNTING RING+DUST SHIELD CAP+SHOX CO2 WELDING

DOCUMENT No.(INDEX)

EQUIPMENTLINE STATION BP SUPPLIER

Maintenance Prevention Information

ESTABLISHMENT PRODUCTION UNIT MMSAI -1302 PUNE

EEM

QCAM

PM

EEM

Shock Absorbers

Quality MaintenanceQuality Maintenance

Thank YouMagneti Marelli Motherson Shock Absorbers India Pvt. Ltd.