Elimination of Rejection due to Journal Unclean at OP140 in Camshaft Line
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This document describes efforts to eliminate rejections due to unclean journal diameters at Operation 140 in the camshaft machining line. Through a root cause analysis, it was found that the faulty pusher design was causing bends in the component from a previous operation. To address this, the team implemented a poka-yoke by changing the pusher design and defining the pressure range to avoid fouling on the heat code and excessive pressure. Testing showed the new design eliminated the rejections at OP140. Process controls like pressure monitoring and tool life alarms were also put in place to sustain the improvement.
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Elimination of Rejection due to Journal Unclean at OP140 in Camshaft Line
- 1. Elimination of Rejection due to Journal Unclean at OP140 in Camshaft Line
- 2. 2 10/17/201 6 Ashok Leyland Presentation (PNR) 1) Select the process 1.1 Select the process for improvement considering the priority - Rejection at OP140 ( Journal diameter Unclean) FY13-14 DEFECT Feedback 1.2 Setting up target :Elimination of Rejection at OP140 (Journal diameter Unclean) OK Not OK
- 3. 3 10/17/201 6 Ashok Leyland Presentation (PNR) 2) System Analysis 2.1 Clarify own process step : Process at Camshaft machining 2.2 Check Defect Step: Op. No. Op. Name 10 Facing & centering 20 Straightening 30 Rough Turning 40 Finish Turning 50 Key-way milling 60 Cam Milling 70 Gundrilling 80 Oil hole drilling 90 H.P. Washing 100 Induction Hardening 110 Tempering 120 Straightening 130 Recentering 140 Journal grinding 150 Cam Lobe grinding 160 Deburring 170 Crack detector 180 Intermediate washing m/c 190 Accurate Inspection 200 Lobe Lapping m/c 210 Phosphating Plant 220 Journal Lapping 230 Washing +Oiling Failure Process that makes In process Defect * Coolant Concentration low becauseconcentration was not checked regularly * Clamping loosedueto hydraulic pressurelow * Wrong measurement doneby an unskilled operator * Gaugefaulty dueto gaugewear out * Measurement variation dueto Gauges / Instrument calibration not doneon time * Wrong Toolsetting by theunskilled operator * Wrong Cutter Offset feeding by unskilled operator * Looseinsert dueto screw wear out * Built Up Edgeon tooldueto variation in coolant concentration * Reusetoolused by unskilled operator. * Wrong Offset feeding by unskilled operator * Tool wear out dueto ToolChangefrequency not adhere * Spindlerunout more * Bench Centrehavemoreerror than accptencevalue * Improper butting of part dueto low tail stock pressure * Fixturealignment setting not proper dueto loosening in mounting or adjusting bolts Reviewed By : Approved By :Part Family: Camshaft PROCESS FLOW DIAGRAM Part Name : H6 Camshaft Part No : X3305611 Prepared By : Online Inspection By Bench Centre CORE TEAM :Mr. Veerapan, Mr. Sandeep Sharma, Mr. Rakesh Panda , Mr.Anil Bhadu,Mr.Harish Karakoti, Mr D.K Pandey,Ms. Taruna Op-130 RE-CENTRING,OIL HOLE DRILLING ON REAR END Base Circle Runout Tolerance-Max 賊 0.075 Yes PFD No : P/EM/M/D/007 Revision No : '000 Revision date : '------ Process Owner:Mr. Sandeep Sharma Key Date : 01.04.2013 Date (Origin) : 01.04.2013 Op 130
- 4. 4 10/17/201 6 Ashok Leyland Presentation (PNR) 2) System Analysis Contd 2.3 Clarify Occurrence condition: Appearance OP140 Journal Diameter unclean Problem : Bend generated from previous operation (op-130) Manufacturing Defective Condition 4M Man N/A Machine N/A Method(X) More pusher pressure 50Bar Material(X) Heat code foul with pusher 2.4 Root Cause Analysis: Occurrence Side: Journal Diameter unclean Heat code foul with pusher & More pusher pressure Excess Bend generated at op-130 2.5 Problem Summary : Pusher Design failure & Pusher pressure not defined in CP Root Cause: Heat Code
- 5. 5 10/17/201 6 Ashok Leyland Presentation (PNR) 3) Poka-Yoke implementation Plan 3.1 Create Idea 3.2 Check Document reflection Poka-Yoke Item Description Target Pusher design changed Before- 1.Heat code foul with pusher 2. High pusher pressure (50Bar) Finished After- 1.Pusher design changed 2. Pressure range defined (15-30Bar) Drawing updated 1. Pusher design changed & Pusher pressure range defined Control Plan & WIS
- 6. 6 10/17/201 6 Ashok Leyland Presentation (PNR) Before Improvement After Improvement Status Before Improvement: Status After Improvement: Journal Diameter unclean due to faulty design of Pusher. New design Pusher eliminate the Rejection due to this Problem. Faulty Pusher design which leads to bend the component during clamping Pusher design change to avoid bending due to fouling with heat code of component during clamping
- 7. 7 10/17/201 6 Ashok Leyland Presentation (PNR) Sustenance: BEFORE AFTER
- 8. 8 10/17/201 6 Ashok Leyland Presentation (PNR) 4) Confirmation 4.1 Time Study 4.2 Compliance No impact in Time Evaluation Item (Opn.no 140 Journal dia. unclean) Effectiveness monitoring TotalAp l1 4 Ma y 14 Ju ne 1 4 Ju ly 14 Au g 14 Se p 14 Oc t 14 No v 14 De c 14 Ja n 15 Fe b 15 Ma rc h 15 Ap l1 5 Ma y 15 Ju ne 1 5 Ju ly 15 Au g 15 Se p 15 Elimination of rejection at OP10 due to reverse loading 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Finished 0 OK X-NGOpn. No Target Result Judge 10 100% 100% 0
- 9. 9 10/17/201 6 Ashok Leyland Presentation (PNR) Production Checked By(BU) Approved By(BU) Checked By(UP) Approved By(UP) DATE Size Freq. Size Freq. Prevention / Error Proofing Detection 1 Holes Dia at Rear End Face ( 04 Nos) 陸 6.0 賊 0.1 PPG/VC 2 Pcs Shift 1 Pc 4 Hrs 2 PCD of Rear End Holes( 4 Nos.) 40.0 賊 0.2 CMM/Receiver gauge 2Pcs Shift 1 Pc 4 Hrs 3 Angle w.r.t Keyway 45 deg CMM --- --- 1 Pc Shift 4 6 hole posn wrt J4 oil hole 0.25 CMM --- --- 2 Pc Shift 5 Speed (rpm) 3500-4000 Program Controlled --- --- 6 Feed ( mm /min .) 400-520 Program Controlled --- --- 7 Tool Life ( Nos.) 175 Program Controlled --- --- --- --- Auto Tool life monitoring M/c Alarm 8 Runout 0.075 Max Bench Center --- --- 1 PC Shift Self Certification sheet ;Product Audit 9 Centre - FE diameter 18 賊 0.2 VC 2 Pcs Shift --- --- 10 Centre - RE diameter 16 賊 0.2 VC 2 Pcs Shift --- --- 11 Speed (rpm) 1600-1800 Program Controlled --- --- 12 Feed ( mm / min .) 120-170 Program Controlled --- --- 13 Tool Life ( Nos.) 800 Program Controlled --- --- --- --- Auto Tool life monitoring M/c Alarm Spotting drill 120 Deg. 15 Speed (rpm) 1800-2200 Program Controlled --- --- 16 Feed ( mm /min .) 150-200 Program Controlled --- --- 17 Tool Life ( Nos.) 1500 Program Controlled --- --- --- --- Auto Tool life monitoring M/c Alarm 18 Speed (rpm) 0 Program Controlled --- --- 19 Feed ( mm / min) 100-300 Program Controlled --- --- 20 Tool Life ( Nos.) 50000 Program Controlled --- --- Auto Tool life monitoring M/c Alarm 21 Low clamping & pusher Pressure 15- 30 Kgf / cm2 Pressure Gauge Once Daily 22 High clamping Pressure 45 - 55 Kgf / cm2 Pressure Gauge Once Daily 23 System Pressure 55 - 65 Kgf / cm2 Pressure Gauge Once Daily 24 Air seat check output (end butting) 0.05 - 0.10 bar Pressure Gauge Once Daily 25 Air seat check output (Orientation) 0.05 - 0.1 bar Pressure Gauge Once Daily 26 Coolant Concentration 05 - 07 % Refractometer Once Daily Daily Monitoring Daily Monitoring Concentration Check Sheet Revision Number : 004 Revision date :01.09.2014 Supplier Plant : Other Approval Date (If Required) : Core Team : Mr. Sandeep Sharma, Mr. Chander Mohan, Mr. Vinod maruya, Mr.Subhanshu Devra, Mr. Anil Bhadu, Mr. D K Pandey Customer Engineering Approval Date (If Required) : CONTROL PLAN Prototype Pre-Launch Key Contact/Phone : Mr. Sandeep Sharma Date (Origin) : 01.04.2013 Control Plan Number : P/EM/M/C/007 Reaction Plan including corrective action Supplier Plant Approval Date :Part Name/Description. : CAMSHAFT- H 6 / H4 Cylinder Recentering & oil hole drilling OP130 As per Process Audit ;Gauge calibration Schedule Evaluation Measurement Techniques Prepared By(CFT) Part No./ Latest change Level : X3305611 / X3307511 Process Supplier Code : Other Approval Date (If Required) : Machine, Device, Jig,Tools for Mfg. Control Method Customer Quality Approval Part/ Process No. Process Name/ Operation description Self Certification sheet ;Product AuditTool Presetting procedure adoption, Auto probing before start of operation, '-on Job Training provided to Operator Characteristic Product BFW - HMC M/C, Drill 6.0 Special characteristic s Methods No. Product/ Process Specification Tolerences Sample Size Operator Sample Size Inspector Process audit Process Audit;Daily Monitoring Check Sheet '- Periodical calibration' '- Alarm will generate & machine will stop in case of any abmormalities or failure Recentering Tool 14 X 60 Deg Pusher design modified to avoid the chances of more runout, Tool Presetting procedure adoption;On Job Training , As per process audit Program locked ,Tool Presetting procedure adoption Process audit ; CMM Inspection As per process audit Program locked by Password. Process auditAs per process audit Program locked by Password. Renishaw Probe RM60 Program locked Process audit As per process audit IN CASE OF NONCONFORMITY STOP THE MACHINE,HOLD THE MATERIAL AND INFORM THE EXECUTIVE & DO 100% INSPECTION Self Certification sheet ;Product Audit Updated Control Plan Pusher pressure range introduced
- 10. 10 10/17/201 6 Ashok Leyland Presentation (PNR) Thanks eliminat ion