action plan of body 0836-049

8/13/2019 Action Plan of BODY 0836-049

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Action Plan of Body 0836-049


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Part Name: Body 0836-049 Qty Found NG: 1 Pc.

Problem: Thread Damaged, with Major

Dia being observed 9.25 MM.

Problem


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A1 Blanking on Traub

A2 Centre-Less Grinding

A4

End-Mill Drilling

Thread-Rolling

Step-Drilling

A3

Chamfer

Final inspection & PA11

Flat-Drilling

A5

A6

A7

Present Process Se

Looking at the NG Component it

concluded that such component

generated at either stage.

Re-ThreadingA8

Free-Hand DrillingA9

PlatingA10


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Understanding The

- The Thread is damaged, wherein the major OD of the component is observed as 9

MM.

- Only the last couple of threads are in shape with the rest being completely damage

Thread Damaged


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A1 Blanking on Traub

A2 Centre-Less Grinding

A4

End-Mill Drilling

Thread-Rolling

Step-Drilling

A3

Chamfer

Final inspection & PA11

Flat-Drilling

A5

A6

A7

Problemati

Re-ThreadingA8

Free-Hand DrillingA9

PlatingA10


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Thread-Rolling Operation


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Fault Analysis (Man)

S. No Potential Cause Validation

1 Unskilled Operator Checked skill status of operator & found upto thedesired level, with a clear understanding of the end

requirement.


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Fault Analysis (Method)


1 Rolling Method Incorrect Observed that the process was correct, as per theindustry standards.

2 Coolant Flow Incorrect Coolant flow was correct, and was flowing evenly

on the surface


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Fault Analysis (Machine)


1 Cycle Time (Spark Out)Inconsistent

Spark Out Time, timer controlled, and timer workingfine.

2 Hydraulic Pressure

Inconsistent

Pressure Controller working fine.

3 Roll Configuration Incorrect Stood correct with regards to the industry standard,

and the required Ra Value

4 Stopper Alignment

Incorrect

Correct, was covering the entire surface of the

component. Height also correct.

5 Hardness of the Roll

Incorrect

Was correct as per the required hardness


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Fault Analysis (Material)


1 Variation in the Hardness Checked, and found it correct as per requirement.

2 Variation in the Dimensions Checked, and found it correct as per requirement.


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Re-Threading Operation


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METHODMATERIAL

UNSKILLED OPERATOR

Cause And Effect Diagram

Any Dimensional

Variation

Re-Threading

Method Incorrect

MACHINE MAN

Die- Size Incorrect

Cycle Time Inconsistent

Die-Setting Incorrect


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Fault Analysis (Man)


1 Unskilled Operator Checked skill status of operator & found upto thedesired level, with a clear understanding of the end

requirement.

2


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Fault Analysis (Method)


1 Re-Threading MethodIncorrect

Observed that the process was correct, as perthe industry standards. However, since the hand

pressure is erratic, too much of pressure results

in thread damage.


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Fault Analysis (Material)


1 Variation in the Dimensions Checked, and found that the profile of the InputThread was correct, with the Gauge Qualifying.


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Fault Analysis (Machine)


1 Cycle Time (Spark Out)Inconsistent

Spark Out Time, is correct, with the Operatorfollowing the required parameters

2 Die-Size Incorrect Correct.


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Why-Why Analysis (FOR OCCURRENCE

Thread flat (major dia. 9.25 observed 9.769.96.

Because of Thread damage .

Because part resting tilted .

Because component alignment was disturbed .

Because of uneven hand pressure .

Because rethreading is a manual process .

Why

Why

Why

Why

Why

Why


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Why-Why Analysis (FOR DETECTION)

Thread flat (major dia. Oversize )

Because of Thread damage .

Setting part mixed with ok parts .

Because of Operator lack of awareness .

Why

Why

Why

Why

Why

Why


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Analysis & Counter

- Results showed that it was at the time of Setting, that such NG Piece could get

generated.

1. Operators at re-Threading once again trained on how to handle Setting

Rejections.

2. Operators at Threading, also proactively trained on how to handle SettingRejections.

3. Operators at Inspection trained to remove such components.

Thread-Damage


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THANK YOU

action plan of body 0836-049

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