JaP

(VE Pump)

A Project Report on Warranty Defect Catalogue, C&D Analysis and various industrial practices.

Submitted by: Puneet Kumar (Summer Trainee)(June 8 to July 22)

Certificate

This is to certify that the project works titled “Warranty Defect

Catalogue” and “C&D Analysis” were carried out by Puneet Kumar

student of B.Tech (Mechanical Engineering) National Institute of

Technology, Kurukshetra under my guidance and has been

completed successfully.

Dated: Remarks:

Acknowledgement

The internship opportunity I had with Bosch JaP was a great chance for

learning. Therefore, I consider myself as a very lucky individual as I was

provided with an opportunity to be a part of it. I am also grateful for

having a chance to meet so many wonderful people and professionals

who led me though this internship period. For that, I’d like to thank Mr. Santosh Joseph for giving me this indispensable opportunity to

experience an industry so close to where I was.

I express my deepest thanks to Mr. Parivesh and Mr. Surendra, my

mentors, for taking part in useful decision & giving necessary advices

and guidance. I choose this moment to acknowledge their contribution

gratefully.

Not to forget to mention Mr. Rahul Jangid, who has helped me

understand things from every direction possible by giving me an idea

about how things might or might not work. So, a very big thank to him.

I’d like to express my gratitude to Mr. Tushar Kulshrestha who guided

me whenever I needed him to.

About Robert BOSCH Group

Chronological Evolution of Bosch logo

The Bosch Group is a leading global player of technology in automotive, industrial, building and consumer goods. The Bosch Group comprises of some 270 subsidiary companies worldwide.

Robert Bosch started this company by opening his small “Workshop for Precision Mechanics and Electrical Engineering”, in Stuttgart in 1886. From these modest beginnings, the Company has long since expanded to become one of Germany’s major industrial enterprises. Since 1964 its majority shareholder has been the non-profit foundation the Robert Bosch Stiftung GmbH. The total sales revenue of the Bosch Group was approximately 52.5 billion Euros. The number of associates employed globally in the three business sectors Automotive Technology, Industrial Technology, Building Technology and Consumer Goods are approximately 305,000.

The special ownership structure of the Bosch Group guarantees its financial independence and entrepreneurial freedom. It makes it possible for the company to undertake significant up-front investments in the safeguarding of its future, as well as to do justice to its social responsibility in a manner reflective of the spirit and will of its founder. 92% of the shares of Robert Bosch GmbH are held by the charitable foundation Robert Bosch Stiftung. In 2012 alone, Bosch applied for nearly 4800 patent applications. This makes Bosch one of the leading companies for patent applications in the world and puts it in the first place in Germany. On each working day, Bosch files19 patents on average.

The Bosch Group is active in the following fields: Automotive technology Automation technology Metals technology Packaging technology Power tools Thermo technology Household appliances Security systems

1899 1900 1907 1919 1931 1981 2004

1914 1925 1931 – c. 1955 1981 2004 Today

Business Sectors

Automotive TechnologyThe name of Robert Bosch is closely associated with the automobile. Bosch, at present time, is

the largest automotive technology supplier in the world with a global group

turnover of 31 billion Euros. The reason for this positive effect is the high

demand for modern diesel-systems. The Robert Bosch GmbH, Stuttgart,

Federal Republic of Germany has been in the forefront of Fuel Injection

technology for almost a century now. Today, this sector, with its headquarters

in Stuttgart, has factories all over the world at 108 locations.

Consumer Goods Business SectorIn India, this sector is engaged in the Power Tools and Security Systems divisions.   Bosch is the

world leader in the power tools segment and has been the pioneer in DIY (Do-it-Yourself) across

different countries, including India. Bosch Security Systems globally has more

than 80 years of experience in fire detection and alarm systems.  In India,

Bosch Security Systems is one of the leading security technology players with

a comprehensive portfolio.

Industrial Technology

Bosch Rexroth AG is an expert for all drive, control and motion technologies. The Industrial

Technology division Bosch Rexroth India provides a complete range of world-class products,

systems and services to customers in India, Bangladesh, Nepal and Sri Lanka

through its manufacturing facilities, service centers, and service partners from

all over South Asia.

Software Services

The software division of Bosch in India is the largest development centre of Bosch outside

Germany. For over 15 years, it has been the preferred engineering services and solutions partner

for the Bosch Group. The software services nurture, build and sustain

enduring customer relationships to enable direct operational and strategic

benefits to our customers.

Ownership Structure

Robert Bosch Stiftung GmbH has a 92% share of equity but no voting rights. Robert Bosch Industrietreuhand KG has 93% voting rights but no share of equity. The Bosch family has 7% voting rights and 7% share of equity. Robert Bosch GmbH has 1% share of equity.

MICO Profile

As he would have wished

As per January 1, 2010 Share Voting RightsRobert Bosch Stiftung GmbH 92%Robert Bosch Industrietreuhand KG 93%Bosch family 7% 7%

Robert Bosch GmbH 1%

Motor Industries Company Limited (MICO) is the flagship subsidiary of the Bosch Group in India. Founded in 1951, MICO is the largest manufacturer of diesel fuel injection equipment in the country; it is also the largest Indo-German company in India.

The nationwide network of MICO spans across 1000 towns with over 4,000 authorised representations ensures widespread availability of both products and after-sales services.

Mico's diverse business areas include common rail injectors and components, diesel fuel injection equipment, industrial equipment, auto-electricals, gear pumps for tractor applications, electric power tools, packaging machines, security technology products and Blaupunkt car audio systems.

Corporate office is located at Bangalore, India; with state-of-the-art ISO and TS 16949 certified manufacturing plants at Bangalore, Naganathapura (near Bangalore), Nashik and Jaipur.

About BOSCH INDIA Ltd.

In India, Bosch is a leading supplier of technology and services, and has a strong presence in the

country at numerous locations in diverse industry segments- both automotive and non-

automotive. Bosch set up its manufacturing operations in 1951, and has grown over the years to

10 manufacturing sites and 7 development centers. In India, the BOSCH Group has over 26,000

employees, and generated a consolidated revenue of Rs. 12,900 crores in 2012.

In India, the Bosch Group operates through four companies –

Bosch Ltd.

Bosch Chassis Systems India Ltd.

Bosch Rexroth India Ltd.

Robert Bosch Engineering and Business Solutions Ltd.

Bosch Automotive Electronics India Private Ltd.

Bosch Electrical Drives India Private Ltd.

With strength of over 26,000 associates, the company has a strong presence the Energy and

Building Technology, Automotive Technology, Consumer Goods and Industrial Technology

sectors. It has a nationwide network spanning across 1000 towns and cities in India with over

4,000 authorized representations which ensure wide spread availability of both products and

services.

BOSCH Limited (Former MICO) in India

Bosch has been present in India for over 50 years, through its subsidiary, Motor Industries

Company Limited (MICO), the name of which was recently changed to Bosch Ltd. In 1951, when

Bosch Ltd. (then MICO) began operations with a two men team in Chennai, its activities were

importing and marketing Bosch automotive products. Soon after, the company setup a

manufacturing plant for spark plugs for petrol engines and fuel injection equipment for diesel

engines in Bangalore.

Bosch limited today is the country’s largest auto component manufacturer and also one of the

largest Indo-Germen companies in India. The Bosch Group holds close to 70% stake in Bosch

Ltd. The company is headquartered in Bangalore with manufacturing facilities in Bangalore,

Nasik, Naganathapura, Jaipur and the recently opened facility in Goa. All the 4 plants are TS

16949 and ISO 14001 certified. Bosch manufactures and trades products as diverse as diesel

and gasoline fuel injection systems, Blaupunkt car multimedia systems, auto electrical,

industrial equipment, special purpose machine, packaging machines, electric power tools and

security systems.

BOSCH Plants in INDIA

Nashik (NaP)

The plant is spread on 400,000 sq m, having 4 manufacturing hangers. In addition to TS 16949;

plant is also certified for ISO 14000, the internationally acknowledged

certificate for Environment protection. Plant is well equipped with latest in

manufacturing, cleanliness and proving of product performance.

Naganathpura (NhP)MICO Naganathapura Plant, inaugurated in the year 1990, is the 3rd Plant

among the 4 plants of MICO. The plant is spread over an area of 231,300 sq. meters and is

situated 11 km away from the Main plant (MICO BanP) at Adugodi, Bangalore. The plant houses

production hangars for Spark Plugs, Glow Equipment, Starter Motors, Alternators, Regulators

and PF Pumps. Portions of the plant are also leased out to RBIN and Bosch Training Center.

Bangalore (BanP)

Founded in 1951, Bosch has been a pioneer and a leader in the Indian automotive segment for

the last 55 years. Certified with TS 16949 and ISO 14001, Bosch Bangalore produces Multi &

Single Cylinder fuel injection Pumps, Common Rail Pumps, Elements, Delivery valves and

components for the VE Pumps. The Bangalore plant won the prestigious “Golden Peacock Eco-

Innovation Award” from the institute of directors.

Goa

It is the fifth location of RBIN commissioned in 2007 at Verna (Goa), devoted to packaging

technology.

Jaipur (JaP)Jaipur plant was commissioned in 1999 with a state-of-the-art manufacturing facility to FIP’s. A

TS16949 certified company; it is a technological oasis in the developing state of Rajasthan.

Jaipur plant manufactures VE (Mechanical and EDC) pumps for domestic market and export

purposes. The VE pump (Distributor fuel injection pump) is designed to Bharat Stage II and

Euro II emission norms. These pumps are used in 3-6 cylinder vehicles.

About BOSCH Plant in Jaipur (JaP)

Jaipur plant (JaP is the fourth manufacturing location of Bosch started in 1999, manufacturing

VE pump for inland and other countries. Jaipur is located in Rajasthan. Bosch’s additional space

requirements up to 2000 were projected to be 102,450 s-m whereas the available space in

existing plants (BanP, NaP, and NhP) was only 72, 150sq.m. Therefore the need for a fourth

location to cater to the needs of the automobile sector was felt.

When Bosch started the selection process for a new manufacturing location in India, Jaipur was

able to prove it better in comparison with the competing locations including the already existing

Bosch locations .As a result, Jaipur was selected as the fourth location for Bosch.

The selected location was Sitapura Industrial Area as it was a developed Industrial estate with

adequate power and water supply and well connected by road, rail and air. Moreover the

government provided better fiscal incentives. March 24, 1999 will go down as an important date

in the annals of Bosch history as the fourth manufacturing plant was inaugurated at Sitapura,

Jaipur by Hubert Zimmer: Chairman (Bosch).

It was set to manufacture Distributor – type diesel fuel injection pumps, a product with

promising growth potential in line with the emerging trends in automobile technology.

The plant started commercial production in December 2000 and was recommended for QS 9000

in December 2000. QS9000 Certificate was issued in March 2001.

Organizational Chart

(JaP) is equipped with 5S.What is 5S?

5S is a method for step-wise improvement of orderliness and cleanliness (O&C) at the

workplace (shop floor and office).

The name 5S represents the first letters of 5 implementation steps.

5S-method has been developed at Toyota.

PT PC

MFA MFC ISY

CFA

HRL

CLPTEFQMM

BPS HSE

OFE-PTMFD DBE

JaP / PM Organization Chart

1. Sort outObjectives:

Identify and eliminate things that are not needed The workplace is for working, not for storing.

2. Set in order Objectives:

A place for everything and everything is at its place.

3. Shine Objectives:

Cleaning involves all senses: seeing, hearing, smelling and touching. Cleaning is Inspection.

4. StandardizeObjectives:

Maintain orderliness and cleanliness There are rules and clearly assigned responsibilities for daily cleaning and inspection.

5. SustainObjectives:

Sustain the rules, standards and regulations Orderliness and Cleanliness are part of daily work and personal attitude.

Customers (in India)

Applications in

Exports in

About VE Pump

Verteiler Einspritz Pumpe (Distributor Injection Pump)

The purpose of the fuel injection pump is to deliver an exact metered amount of fuel, under high pressure, at the right time to the injector. The injector injects the fuel directly into the cylinder or a pre chamber connected to the cylinder.

As the name depicts, pump automatically distributes fuel among all the cylinder of the engine in a complete cycle by providing rotating and reciprocating motion to the distributing parts. By doing this, it simultaneously compresses and distributes fuel giving us a very compact mechanism of a pump.

Advantage offered :

VE Pump has a distinct advantage of compressing and delivering the fuel to the injector by a very compact mechanism, even for multiple cylinder engine.

Basic Working of a Diesel Engine running with the help of a VE Pump.

Major Parts of a VE Pump

1. Vane supply pump with pressure control valve: Fuel induction and generation of internal pump pressure

2. High-pressure pump with distributor head: Generation of injection pressure, fuel delivery and distribution to individual engine cylinders

3. Mechanical governor: Controls rotational speed; control mechanisms vary delivery quantity in control range

4. Solenoid -operated shutoff valve (ELAB): Interrupts fuel supply to shut off engine

5. Timing device: Determines start of delivery as function of engine speed and (partially) engine load

Functioning of a VE Pump

Fuel enters the VE Pump at a Pressure of 2-3 bars and is compressed to a pressure of 6-8 bars by the feed pump rotating with half the speed of engine( in case of 4 stroke engine). Pressurized fuel then now is compressed by the reciprocating motion of the plunger in the distributor head to a pressure of 700 to 800 bars to and exits through the fittings present individually for every cylinder.

About QMM

Quality Management and MethodsFunction: Maintains the quality of the product processing and defines various methods to improve it.

"It has always been an unbearable thought to me, that someone could prove, on testing one of my products, that I produce anything of inferior quality. I have therefore, always tried to let only such work go out, that would stand any objective test, work that was of the very best quality." "I have always acted on the principle: 'Rather lose money than the confidence of the customers.' The integrity of my goods and my given word always meant more to me than temporary gain."

Robert Bosch (1861-1942) Founder: Robert Bosch GmbH Germany

Quality principles:

Our goal is to fully satisfy our customers’ expectations through the quality of our products and

services Quality and quality improvement is every associate's responsibility and ultimate goal from the

board of directors to apprentices Our directives, processes, systems and goals are based on requirements from international

standards, customer expectations, our knowledge and experience.. Knowledge of and

compliance with these directives and processes is the foundation of our quality. Quality means doing things right in the beginning, thus preventing failures in the end.

Continuous improvement of the quality of processes lowers costs and increases productivity. Avoiding failures is more important than eliminating defects. We systematically apply methods

and tools for preventive quality assurance, learn from mistakes and eliminate their root causes

without delay Our suppliers contribute substantially to the quality of our products and services. Therefore our

suppliers must live up to the same high quality standards we have adopted.

Organization Chart for QMM

QMM1 Functioning.

Quality Management and Methods (QMM)

QMM1Customer Support

Group

QMM 7System Audit

QMM 8Metallurgical Lab

QMM 9Product and

Component Audit

CustomersPlant

Manufacturing

Mr. Customer

Taking up as a team

Mr. Customer

Direct interaction with customers

Process Audit

System Audit Coating Thickness

Composition Inpection

Chemical Lab

C & D Analysis

Barrier Audit

Component Audit

Quality (Pro-active /Reactive measures)

Feedback

Design

Application

Sales

Support team

About Learnings

Miscellaneous:

What is a Distributor Injection Pump (VE Pump)

Functioning of VE Pump

Add-ons to VE Pump

Manufacturing of components

Sub-assemblies of components

Assembly of VE Pump (HoP and FeP)

Product Processing throughout the Plant

Chip & Dirt Analysis of Housing and Pump

Investigation of complaint

Machine Capability Calculation and Validating Normal Distribution Curve

Major Projects Done: Defect Catalogue upgrade

Study of Chip reduction methods for Pump Housing

Study of Machine Capability Calculation and Verification

PCV Leakage cause identification

Defect Catalogue Improvement

What is Defect Catalogue and Why is it so important?

Defect Catalogue (aka Warranty Defect Catalogue) is like a Company‘s Guideline Database so as to classify different field complaint to be entertained or not. It is company‘s responsibility if the complaint is concerned with any manufacturing defect or inability. This catalogue is for internal circulation within the company or Bosch Dealers. The process flow of communication is following:

After reaching Bosch Dealer, Pump will be analysed for defects and Warranty Defect Catalogue will be referred for the concerned defects present. They will look for the defect in the catalogue and finds if it is the company’s responsibility in which it is clearly written if it is to be accepted or rejected to make it easier for the Bosch Dealer to decide. And if it is to be accepted then the repairs are done there-itself and if needed sent in the workshop

OEM Engine Manufacturer/Vehicle

AssemblyVehicle Seller End Customer

VE Pump

OEM Service

Complaint

Bosch Dealer

Pump Problem

Refer Defect Catalogue

Samples of Warranty Defect Catalogue:

For Reference Only

For Reference Only

For Reference Only

C&D Analysis of Pump Housing:

Chip and Dirt AnalysisWhat is Chip and Dirt?

Chip and Dirt are the unwanted, separate small pieces of material which are present in every component and may cause serious damages under high pressure processing. The Chip is formed due to mainly two reasons , one is that the surface is not so fine as required & other is that the holding or binding capacity of material is less. The Dirt may come from environment, from the oil that is used to run the pump or from the operators‘ mishandling.

Why C&D Analysis is done?

Chip and Dirt, if present, during the working of the pump may cause major damages to other components.

In case of used pumps, C&D is done for the whole pump by flowing fuel like liquid in the pump which is powered by a bench electrically. Fuel then is used for C&D Analysis by filtering it through filters. The chip and dirt is then analysed for chemical composition using SEM, which gives the idea of which component might be troubling or producing chip and dirt.Whereas research is done on fresh components, so as to improve the production and cleaning techniques previously used. If a specified limit (according to the norms of the company) is surpassed, then practices are moved in direction to change the course of processing the component.

What was the project about?

Pump Housing is casted by several suppliers outside the plant. C&D analysis were done for each supplier on regular basis for quality control purposes.

Housing from several suppliers were found to be having much more C&D than the specified limits. Hence, efforts were made by the team to reduce the chip and dirts before it reaches for production.

What were the efforts made?Several Trials were done following from the next page.

After Trial 4, same process is followed in the next trial as positive results were expected from it.

Observations:

Result: After doing several trials as above Chip and Dirt was reduced to more than half compared to what was produced before the trials. Comparing to the un-cleaned sample Chip and Dirt were reduced by about an mg in weight.

Machine Capability:Machine Capability is formulated as

Cm = Tolerance/ (6*SD)

It helps calibrating the machine according to the required dimensions and size of the component being produced.Acc. To Bosch norms,for being in a safer zone machine capability should be greater than 1.67 as defined that maximum products should lie under 60% of the tolerance limit (only abt. 1 ppm defects).

Inspection was done on a machine to validate and check if it is working fine.Analysis of the inspection:

Machine CapabilityMachine : Junker

Plunger Slot Grinding ProcessTolerance: 0.2

Control Limits : NA (Not to be Shared) USL : NA ; LSL : NA (Not to be Shared)

S. No. Abs. Reading

Frequency

1 5.45 12 5.46 33 5.47 44 5.48 75 5.49 136 5.5 247 5.51 248 5.52 329 5.53 9

10 5.54 211 5.55 1

Standard Deviation (SD)

√{Σ(X-Xᵢ)²/(n-1)} 0.018260

Machine Capability (Cm)

Tolerance / (6* SD)

1.8254

Machine Status

OK