Analysis of online defects in mass production of automobile
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Transcript of Analysis of online defects in mass production of automobile
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8/10/2019 Analysis of online defects in mass production of automobile
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nalysis of online defects in mass production of
automobile
By:
VARUN MALIK
M.Tech - Auto
A2326213033
Under the guidance of:
Prof. VIVEK KUMAR
HoD, MAE
Amity University, UP
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Vehicle Inspection department is responsible for the following :
1. Safety - Zero Accident
2. Quality
GCA(Global Customer Audit ) Score Improvement
PDI(Pre delivery inspection ) Defect percentageReduction
Defect Free vehicle to customer
3. Capability Development
4. Operational Cost Reduction and Productivity Improvement
5. New model quality Up gradation and sustenance
A GLIMPSE OF VI
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VEHICLE INSPECTION 1 PROCESS SEQUENCE
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DRUM
TESTER
DYNAMIC CHECKING OF VEHICLES FOR
CHECKING VEHICLE PERFORMANCE
BRAKE
TESTER
FUNCTIONING OF FRONT / REAR BRAKES
AND PARKING BRAKES
6 ENGINE ROOM
1. EMISSION CHECKING AS PER
REGULATIONS
2. WIRING AND PIPING CHECKING INSIDE
ENGINE ROOM
7PIT
INSPECTION
UNDERBODY INSPECTION FOR COOLANT ,
TRANSMISSION OIL, ENGINE OIL LEAKAGE
5
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8 SHOWERTESTER
WATER LEAKAGE CHECKING INSIDEPASSENGER CABIN
9 ROAD TESTDRIVING PERFORMANCE CHECK ON ROAD
TESTING
10FINAL
INSPECTIONRECHECK OF REPAIRED DEFECTS.
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SHOP LAYOUT
FIRST PPER NCE CHECK
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SHOWER TEST
SHOWER TEST
H LF RO D TEST
RO D TEST
FIRST PPER NCE CHECK
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PROJECT TITLE
Analysis of online defects in massproduction of automobile
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REQUIREMENT OF THE PROJECT
CUSTOMER
SATISFACTION :
LOSS IN QUALITY
EXTRA MOVEMENT OF NGVEHICLES
EXTRA
REPAIR
EXTRA TIME CONSUMPTION
LOSS IN
EFFICIENCY
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ADOPTED METHODOLOGY
GENCHIGO TO THE ACTUAL PLACE
GENBUTSUOBSERVE THE ACTUAL THING
(GENJITSUACT TO RECTIFY THE PROBLEM)
EXECUTION OF SUZUKIs 2G/3G
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A. TESTER LINE DEFECTS - RESULTS
Defects
0
10
20
30
40
Defects
Trend of Total Defects per day
Omni
Eeco
Wagon R
Ritz
Alto-800
Model wise bifurcation
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A. TESTER LINE DEFECTS - RESULTS
20 May
Omni
Eeco
Wagon R
Ritz
Alto-800
21 May
Omni
Eeco
Wagon R
Ritz
Alto-800
22 May
Omni
Eeco
Wagon R
Ritz
Alto-800
23 MayOmni
Eeco
Wagon R
Ritz
Alto-800
24 May
Omni
Eeco
Wagon R
Ritz
Alto-800
Omni
Eeco
Wagon R
Ritz
Alto-800
26May
Omni
Eeco
Wagon R
Ritz
Alto-800
27 May
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A. TESTER LINE DEFECTS TOP 3 DEFECTS
EECO
S.No. Type of Defect Quantity Department1 CNG Pipe fouling with body/AC pipe 7 AS
2 Clutch pedal play excess/nil 4 AS
3 Headlight Focus Not OK/ Headlight Motor Not OK 4 SQA
Omni
S.No. Type of Defect Quantity Department
1 Headlight Focus Not OK/ Headlight Motor Not OK 50 SQA
2 Accelerator Pedal play excess 7 AS
3 Fuel Pipe fouling with body 3 AS
Ritz
S.No. Type of Defect Quantity Department
1 Engine Late Start 9 Engine Shop
2 Clutch Pedal Play Excess 6 AS
3 Engine Oil Splash from oil filter 2 AS
YR9
S.No. Type of Defect Quantity Department
1 Engine RPM High 19 Engine Shop
2 Gear Operation Sticky/Not OK 9 Engine Shop
3 Clutch Pedal Play excess 4 AS
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A. TESTER LINE DEFECTS TOP 3 DEFECTS
1. Headlight Focus Not OK/Headlight motor Not OK
0
5
10
15
20
25
Omni
Eeco
Wagon R
Ritz
Alto-800
Reason:
The Headlight defects
are associated with SQA
(Supplier Quality
Assurance).
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A. TESTER LINE DEFECTS TOP 3 DEFECTS
2. Engine RPMHigh
0
0.5
1
1.5
2
2.5
Omni
Eeco
Wagon R
Ritz
Alto-800
Model Variant RPM
Omni MPI 900 +/-50
Gypsy MPI 750 +/-50
EECO MPI (Petrol/CNG) 800 +/-50
RITZ Petrol 700 +/-50
RITZ Diesel 800 +/-50
YR9 Petrol/CNG 700 +/-50
YR9 Biofuel 880 +/-50
Analysis of reasons1. Accelerator cable playNill
2. Intake Air Control Valve Pin backup
3. Main harness bent
4. Throttle body problem5. Vacuum pipe out
6. Low Coolant
Engine RPM Standards
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A. TESTER LINE DEFECTS
3. Engine late start
0
0.5
1
1.5
2
2.5
3
Omni
Eeco
Wagon R
Ritz
Alto-800
Analysis of reasons
a. Timing Belt Failure
b. Distributor Failure
c. ECM Failured. Vehicle out of fuel because
of inaccurate fuel gauge
e. Carburetor problem
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B. SHOWER LINE DEFECTS - RESULTS
Defects
0
10
20
30
16-Jun
17-Jun
18-Jun
19-Jun
20-Jun
21-Jun
22-Jun
Trend of Total Defects per day
Model wise bifurcation
Omni
Eeco
Wagon R
Ritz
Alto-800
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B. SHOWER LINE DEFECTS TOP 3 DEFECTS
EECO
S.No. Type of Defect Quantity Department
1 Rt/Left Sliding door sliding hard 14 AS
2 Back door closing hard 9 AS
3 Rt/Lt Rear Door Opener Play 7 SQA
Omni
S.No. Type of Defect Quantity Department
1 HMSL Noise 12 AS
2 Rt/Left Door gap not OK 8 AS
3 Rt/Left Door Opening Hard/Sticky 7 AS
Ritz
S.No. Type of Defect Quantity Department
1 Left/Right Warehousing Level Diff Not OK 3 AS
2 Back Door Gap Not OK 1 AS3 Back Door Catch Noise 1 AS
YR9
S.No Type of Defect Quantity Department
1 Back Door Operation Hard 7 AS
2 Rt/Lt Front Door Glass Rungap not OK 5 AS
3 Alarm Sound Not Working 4 AS
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B. SHOWER LINE DEFECTS - RESULTS
Omni
Eeco
17 June
Omni
Eeco
16 June 18 June
Omni
Eeco
Omni
Eeco
Wagon
R
19 June
Omni
Eeco
Wagon
20 June
Omni
Eeco
Wagon R
Ritz
Alto-800
21 June
Omni
Eeco
Wagon R
Ritz
Alto-800
22 June
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B. SHOWER LINE DEFECTS TOP 2 DEFECTS
1. Back Door Operation Hard
Frequency
0
2
4
6
8
10
OmniEeco
Wagon RRitz
Alto-800
Frequency
Reason :
This defect is attributed to
Assembly Shop
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B. SHOWER LINE DEFECTS TOP 2 DEFECTS
2.Sliding Door Play
0
2
4
6
8
10
12
14
Omni Eeco Wagon R Ritz Alto-800
Frequency
Reason:
This defect is also
attributed to
assembly in
Assembly Shop
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QUALITY ASSURANCE : MAJOR DEFECT ELIMINATED.
COST SAVINGS : RECHECKING OF VEHICLES ELIMNATED.
PRODUCTIVITY INCREASE
TIME SAVINGS
FINAL ACHIEVEMENTS OF THE PROJECT
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Thank You ! ! !
Any Questions ?