Project Presentation

By:- Mohit GuptaRoll No:- ME-10-B(TC)-40

Department:- Quality Analysis

@

GABRIEL INDIA LTD. PARWANOO

PROJECT:-Reduction of Internal Rejections During the Process

Objective:-

To decrease the internal rejections that is various defects like Piston Rod Burn, Low Tension, Nugget Failure, Thread Damage, Overflow, Paint on Piston Rod.

To track the root cause of these internal rejections. To Suggest measures to minimize these problems.

How This Project Link up With My Course..?

This project gave me an opportunity to use various measuring components which is a key area of engineering meteorology.

This project also gave me the opportunity to know about precision and accuracy which forms a key feature in quality analysis and meteorology.

ROAD MAP ( 1st JAN – 30th JAN)

Learned about the various assembly process carried out in the plant.

Type of defects and their probable causes. Analyzed different defects like thread damage,

overflow and nugget failure. Prepared Fishbone Diagrams regarding defects.

Fishbone Diagram for:-Defects in Paint Shop

Piston Rod Burn

ManMethod

MachineMaterial

Measurement

Upper electrode welded the metal stop from side instead of topManual Error

Misalignment of upper electrode and piston

rod

Indexing fixture bolt loose

Checking frequency not defined and no checking mechanism of bolt

Fishbone Diagram for:-Defects in Paint Shop

Dent Mark in Paint Shop

ManMethod

MachineMaterial

Measurement

During Cleaning Sometimes Application Falls Down Manual Error

Improper Hanging Dent From the Previous operation

Rough Loading and Unloading

Fishbone Diagram for:-Defects in Paint Shop

Rough Surface-Presence of dust Particles

ManMethod

MachineMaterial

Measurement

Environmental Dust

Manual Error

Paint-Primer Combination not ok

Conveyer Belt not Clean

Improper Phosphate Coating

Dusty Hand Gloves Used

Fishbone Diagram for:-Defects in Paint Shop

Overflow

ManMethod

MachineMaterial

Measurement

Improper Cleaning

Manual Error

Paint-Primer Combination not ok

Bubbling in the Paint Gun

More Rotation of ConveyerPhosphate Coating not ok

Paint Primer Combination not ok

Fishbone Diagram for:-Defects in COMBI Line

Thread Damage

ManMethod

MachineMaterial

Measurement

DFT(Damping Force testing) Alignment not okManual Error

Material Composition not ok

Unskilled Man Power

Brass Holder not ok

ROAD MAP(1st FEB-28th FEB)

Post problem analysis was done. Learned about the causes of piston rod burn on

metal stop welding m/c. Implemented measures for eliminating piston rod

burn using 4 bolt indexing fixture. Implemented part direction sequence to reduce

rejection due to low tension.

Post Problem Analysis Report-1Before:-Metal Stop Welding Machine Causing Piston Rod Burn After :- Four bolt is used instead of two bolt in indexing fixture.

Before After

Post Problem Analysis Report-2Before:-Internal Rejections due to Low Tension that is due to part reversed. After :- Part direction reversed.

Before AfterPart

direction Reverse

Part direction ok

OUTLOOK

BEFORE: In ALTO PISTON ROD the internal rejection of 16 no’s worth Rs 2576

were analyzed. In INDICA REAR the internal rejection of 3 no’s worth Rs 468 were analyzed.

AFTER: Now four bolt is used instead of two bolt in indexing fixture and piston

rod burn is removed . Part direction sequence is implemented hence rejection due to low

tension is decreased.

Result Root cause of internal rejections were tracked and measures were

suggested. Piston Rod burn on metal stop welding was eliminated using four

bolt indexing fixture.

Rejection due to Low Tension decreased by implementing part direction sequence.