Mohan Report

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    CHAPTER 1

    INTRODUCTION

     

    1. 1. INTRODUCTION

    Today many of the small scale manufacturing companies in United States are facing problems in

    order to become competitive in global market. One of the reasons is the manufacturing activities

    are outsourced to low labor cost countries like India and China. (han! "! #$%$& 'owa)ays

    due to an increased competition companies are looking forward to reduce total cost! lead times

    and increasing the product *uality. This has created a need to implement lean and si+ sigma

    strategies in manufacturing organi,ations. -ean Si+ Sigma approach to business process

    improvement helps companies distinguish themselves from competitors by manufacturing

     products with less waste! faster! better and at lower cost. -ean Si+ Sigma is a methodology! when

    it implemented properly the company improves efficiency and gain competitive edge. Today

    organi,ations are using different tools and techni*ues to improve and sustain in the market.

    Currently! Si+ Sigma tools and -ean anagement are recogni,ed as most popular continuous

    improvement initiatives and companies are using them widely. -ean Si+ Sigma pro/ect initiatives

    start with understanding the current state of the 0usiness processes in organi,ation! then setting

    up targets for future state of all activities. Si+ Sigma uses )1IC ()efine! easure 1naly,e

    Improve and Control& framework and -ean uses tools like value stream mapping!2S program!

    Single piece flow etc. Using these tools and techni*ues organi,ation can improve business

     processes! the obstacles to achieve these improvements can be addressed by kai,en event. (Chen!

    #$%$&

    This pro/ect shows reduce the coolant consumption in tractor rim liners. To reduce the coolant

    consumption by applying -ean Si+ Sigma tools such as Cause and 3ffect diagrams! root cause

    analysis and brainstorming etc. This 4ro/ect addressed the root causes of problems in the process

    of coolant consumption and recommended solutions and alternatives which led to more

    optimi,ed processes and enhanced the operational system! eliminate different type of waste! and

    increased the profit.

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    1.2 COMPANY BACKGROUND

    1.3 LEAN MANAGEMENT & SIX SIGMA

    1 lean system emphasi,es the prevention of waste in terms of any e+tra time! labor! or material

    spent producing a product or service that doesn5t add value to it. 1 lean system5s uni*ue tools!

    techni*ues! and methods can help organi,ation to reduce costs! achieve /ustintime delivery! and

    shorten lead times. 1s -ean systems are customer focused and driven this approach makes sure

    that products or services produced and delivered at right time in right *uantity at right location at

    right time with minimum costs incurred. 1 lean system allows production of a wide variety of 

     products or services! efficient and rapid changeover among them as needed! efficient response to

    fluctuating demand! and increased *uality. -ean approach encourages the rapid response to

    customer ever changing demands with focus on mass customi,ations rather than mass

     production. -ean systems make the work flow more efficient! productive! and fle+ible to changes

    in re*uirements. (aclnnes! #$$#&

    6Si+ Sigma is a factbased! datadriven philosophy of *uality improvement that values defect

     prevention over defect detection.7 (0rassard! #$$#& Si+ Sigma is also business philosophy of 

    focusing on continuous improvement by understanding customer needs! understanding current

     business processes! and applying data collection methods. It is also methodology for organi,ation

    to make sure those improvements done to improve the key processes. Si+ sigma tools and

    techni*ues also used to identify which business process in the organi,ation would be benefited

    most due to improvement effort.1.3.1 Brains!r"in#

      It is a group or individual creativity techni*ue by which efforts are made to find a

    conclusion for a specific problem by gathering a list of ideas spontaneously contributed by its

    members.

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    1.3.2 Ca$s% an %''%( ia#ra"

      It is also called fish bone diagram show the significant and insignificant actions during a

     process. It identifies many possible causes for an effect or problem and sorts the ideas into useful

    categories. Often the e+perience of the speciali,ed knowledge of engineers and scientists

    dominate the selection of factors.

    1.3.3 R!! Ca$s% Ana)*sis

    The 8ive 9hys approach to root cause analysis is often used for investigations into e*uipment

    failure events and workplace safety incidents. The apparent simplicity of the 29hys leads

     people to use it! but its simplicity hides the intricacy in the methodology and people can

    unwittingly apply it wrongly. They end up fi+ing problems that did not cause the failure incident

    and miss the problems that led to it. They work on the wrong things! thinking that because they

    used the 29hys and the *uestions were answered! they must have found the real root cause.

    1.+ OB,ECTI-E O THE STUDY

    To determine the most critical :5s in the coolant consumption process and to eliminate the ;ital

    :5s in the process to reduce the coolant consumption in tractor rim line.

    1./ ORGANI0ATION O THE REPORT

    This section provides a brief overview of the chapters for the convenience of the reader to easily

    e+plore the contents of the report. In chapter# deals with literature review on reduce the coolant

    consumption process using lean si+ sigma methodology. The problem statement and

    methodology in chapter

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    ;arious work done on the welding process! optimi,ation of weld parameters by using the

    statistical optimi,ation techni*ues are presented in the chapter.

     2.1 TIG %)in# & Ta#$(i %(ni4$%

       'irmalendhu!et al.! (#$%=& analy,ed to the improvement of ultimate load of stainless

    steel > mild steel weld specimen made of tungsten inert gas (TI?& welding. -%@ orthogonal array

    (O1& of Taguchi method has been used to conduct the e+periments using several levels of 

    current! gas flow rate and filler rod diameter. Statistical techni*ues analysis of variance

    (1'O;1&! signaltonoise (SA'& ratio and graphical main effect plots have been used to study

    the effects of welding parameters on ultimate load of weld specimen. The optimum welding

    condition obtained by Taguchi method isB current %$$ 1! gas flow rate %D lAmin and filler rod

    # mm. Confirmation test is confirms the improvement of the U- which also indicates the

    validity of the present optimi,ation.

     1vinash!et al.!(#$%

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      Orthogonal arrays of Taguchi! the signaltonoise (SA'& ratio! the analysis of variance

    (1'O;1&! and regression analyses are employed to find the optimal process parameter levels

    and to analy,e the effect of these parameters on the weld properties. Confirmation test with the

    optimal levels of welding parameters was carried out in order to illustrate the effectiveness of the

    Taguchi optimi,ation method. 8rom the analysis of the results using the signaltonoise (SA'&

    ratio approach! analysis of variance and Taguchi5s optimi,ation method! the following can be

    concludedB 4eak current of %2$1! base current of H21 and pulse fre*uency of %2$ , are the

    optimi,ed welding parameters for getting highest microhardness! smallest e*iu+ed weld grains

    and minimum 1" width. Out of three selected parameters! peak current has the highest

    contribution i.e. @%.2DJ.

      4asupathy!et al.! (#$%

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    ishore!etal.! (#$%$& have analy,ed the effect of process parameters in *ualitative manner 

    for welding of 1ISI%$=$ steel using processes of Shielded etal ?as 9elding (I? and TI?&.

    Taguchi method is used to formulate the e+perimental layout arc voltage! arc current! welding

    speed! no,,le to work distance and gas pressure predominantly influence weld *uality! even plate

    thickness and backing plate too have their own effect. )esign of e+periments based on

    orthogonal array is employed to develop the weldments. 1n -D orthogonal array is selected for 

    e+perimentation. The total variables are seven hence # H e+periments are re*uired for perfect

    analysis! however it is impractical! time consuming and e+pensive to conduct such large number 

    of e+periments .

      The result computed is in form of contribution from each parameter! through which

    optimal parameters are identified for minimum defects. The e+periments with low current has

    increased the J of variance of -O4 in both TI? and I? welding .igh welding speed resulted

    in under fillF it is as high as Dmm# in TI? weldingF -ack of penetration is largely influenced by

    the plate thickness in TI? weldingF current has an influence of about =2 J on under fillF

    2.2 S5a%r D%'%(s

     

    Teerade/! et al.! (#$%$& studied to determine an optimal condition of resistant spot welding

     process in order to reduce a welding spatter problem. there were four factors considered as high

     potential causes of welding spatters. They selected the factors are 3lectrical supply >single

    !dual!aterial thickness heavy !normal! 9elding angle perpendicular! non

     perpendicular!9elding position middle!flange 3ach factor consider as three levels and #⁴

    factorial e+periment also conducted to test the effects of all possible combinations.

      The result showed that three main factors namely 3! 91! and 94 had significant effects to

    the defective parts whereas T was not significant.The optimal condition obtained from the

    e+periments by using single pulse signal! normal thickness! perpendicular angle! and middle

     position! a number of defective parts were reduced significantly from %#J to

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    CHAPTER 3

     

    PROBLEM STATEMENT AND METHODOLOGY

    3.1 Pr!5!s% M%!!)!#i%s

    3.1.1 DMAIC M%!!)!#*

    )1IC methodology involves 2 steps )efine! easure! 1naly,e! Improve! and Control. This

    method can be used to improve the current capabilities of current process where based on data

    driven conclusions future state can be established.

    D%'in% Pas%6  The goal of define phase is to define the pro/ect scope by understanding

     background information about the process and its customers. Tools used in define phase as voice

    of customer! pro/ect charter are used decide the scope of pro/ect and define boundaries of 

    improvement effort. It also identifies key stakeholders! time lines! improvement priorities! and

    improvement targets at the beginning of pro/ect. The best representation of define phase can be

    established by oshin planning or + matri+.

    M%as$r% Pas%6 The goal of measure phase is to focus on improvement effort by gathering

    information about current state of the process. Team has created data collection templates

    according the area of improvement and worked on getting first hand data. easuring the right

    data which can pin point location! occurrence point and rate of occurrence is re*uired to decide

    the improvement priority and problem5s location. In measure phase team can gather istorical

    data to come up with baseline for improvement. easure phase data collection effort leads to

    more focused problem statement.

    Ana)*7% Pas%6 The goal of analy,e phase is to establish the root causes of the problem and

    confirm them with the data points. 1naly,e phase helps in collecting causes of the problem to

    come up with root causes. 0raining storming! cause and effect diagram! histogram and fishbone

    diagram are some of the tools which can be used in analy,e phase of the improvement.

    I"5r!8% Pas%6 The goal of improve phase to work on improvement solutions based on define!

    measure and analy,e phase outputs. Improve phase compares before and after process status to

    develop and implement the process improvements. Improve phase not only generates the

    solutions but also give feedback mechanism check the effectiveness of improvements.

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    C!nr!) Pas%6 The goal of the control phase is to maintain and standardi,e the gains of the

    improvements. Control phase also re*uire a continuous improvement effort to sustain the change.

    Customer changing re*uirements need ma/or changes in process flowsF in that case improvement

    team should be able to analy,e the changes for further improvements.

    CHAPTER +

    DMAIC METHODOLOGY

    +.1 DEINE

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    The 4roblem is defined in this phase. Geduction of coolant consumption in tractor GI line is

    targeted. 9ith the help of process mapping! various stages in the rims process are identified is

    shows the figure =.%.

    Pr!9)%" Sa%"%n6  Geduction of coolant consumption in tractor GI line

    Pr!:%( S(!5%6 Gework cost reduction K Muality improve

    Tar#%6 onthly 2$$ litres to #$$ litres

      i# +.16 Pr!(%ss Ma5 !' Tra(!r Ri" Lin%

    +.1.1 I%ni'i(ai!n !' % Pr!9)%"

    The problem description helps where the problem is locatedAoccurred is shown in the table =.%.

    Ta9)% +.16 I%ni'i(ai!n !' Pr!9)%"

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    +.1.1.2 Ca%#!ri7ai!n

    • TYPE A ; inimum involvement of other department in solving them A can be solved by

    the MC member itself.

    • TYPE B ; Involvement of other department is a necessity.

    • TYPE C ; 4roblem can be solved with management assistance.

    +.1.2 S%)%(i!n !' Pr!9)%"

    10

    A < 1 3

    C < 2B < +

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    To identify the problem is located in GI line. Then to found the causes of the problem is based

    on ranking related to product! *uality! cost! delivery! service! work environment is shows table

    no.=.#.

    Ta9)% +.26 S%)%(i!n !' 5r!9)%"

    P=Pr!$(i!n> ?=?$a)i*> C=C!s> D=D%)i8%r*> S=Sa'%*> E=!r@ En8ir!n"%n

    +.2 M%as$r% Pas%

     )uring this phase! the key processes in the pro/ect lifecycle that affect the CTM (in this case!

     product *uality&! were identified to be pro/ect study! e+ecution and delivery. easurements

    related to the CTM are made in these phases. The field errors captured by the =9K%!root cause

    K 9N 9N analysis as shown in 8igure =.#.%.

    +.2.1 + & 1H Ana)*sis

    The =9 K% is e+plained the 91T is the problem and 93G3 it is occur and 93' it is

    occur! 9O K O9 much is the severity of the problemAprocess as shown in the figure =.#.%.

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     Why?

      Why?

      Why?

    Rim operation improper lubrication used

    Coolant contamination changed

    Rim scufng and scoring mark high

    Foreign particles mix-up

      Why?

      Why?

    Exist design11

    CO!"ER #E$%RE

    $ %ystem to be pro&ided to Re coolant cycle syste

    i# +.2.16 +&1H

    +.2.2 R!! Ca$s%s & * =* Ana)*sis

    It is one of the simplest investigation tools easily completed without statistical analysis. 1lso

    known as a 9hy Tree! it is supposedly a simple form of root cause analysis. 0y repeatedly

    asking the *uestion! 9hyP5 you peel away layers of issues and symptoms that can lead to the

    root cause of the coolant consumption as shown in figure =.#.#.

     

    12

    D$rin# % !5%rai!n ir!n 5ars "i% an s% $5

     

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    i# +.2.26 HY=HY ana)*sis

    +.3 Ana)*7% 5as%6 4rocess performance was assessed using Causeand 3ffect diagrams! to

    isolate key problem areas! to study the causes for the deviation from ideal performance! and to

    identify if there is a relationship between the variables. 3+tensive brainstorming sessions were

    held with team members to evolve these diagrams. 8igure =.

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    +.3.1.2 Ca$s% an E''%( ia#ra"

    -arge variation has been reported in the first phase. To reduce variations! analy,e the machine

    and identify some factors which may affect the variation. 8inally! a fishbone diagram is formed

    as shown in 8igure =.

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    M S PROBLEMCONSIDERED NOT

    CONSIDERED

    REASON OR

    ELIMINATION

    Man I"5r!5%r (!!)an !i) "i% C!nsi%r%

    Man Uns@i))% !5%ra!r C!nsi%r%

    Man I"5r!5%r (!!)an !i) ')! C!nsi%r% SOP A8ai)a9)%

    Man In(!rr%( L!(ai!n !' ri" N! (!nsi%r% P%ri!i( PM

    Man T!!) )i'% #!n% N! (!nsi%r% P%ri!i( Ins5%(i!n

    Ma(in

    %C!!)an (!na"inai!n C!nsi%r%

     

    M%! T!!) :a n! s$''i(i%n N! (!nsi%r% P%ri!i( PM

    Man C!!)an s5i))a#% in ')!!r C!nsi%r%

    Ma%ria

    )L%ss%r i(@n%ss "a%ria) N! (!nsi%r%

    C%(@ 5!in in irs !''

    ins5%(i!n

    M%!as% an #r%as% "i%

    (!!)an !i)C!nsi%r%  

    M%!

    I"5r!5%r (!!)an 5i5%

    r!$in# N! (!nsi%r%

    E5anin# B)!(@ s%in# 9*

    PTA

    Ma(in

    %

    L%a@a#% * !i) "i% '!r

    (!!)anC!nsi%r%

     

    +.3.1.+ A'%r E)i"inai!n !' Min!r E''%(s = Ca$s%s & E''%( Dia#ra"

    15

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    i# +.3.2 E)i"inai!n !' Min!r E''%(s

    +.3.1./ E''%(s !' % Pr!9)%"

    Gim Gework more

    Gim *uality effect for rim rust form problem high

    Gim scuffing mark and scoring mark high

    Our internal customer Gim feeding time delay

    4ickling cost very high

    igh operator fatigue and Skilled operator is re*uired

    +.3.1. I"5!ran(% !' % Pr!9)%"6

    achine bit accumulated coolant oil daily cleaning and fill up the barrel .

    9eekly @ barrel oved to 3T4 plant

    Coolant removed out e+tra #man power and barrel moved forklift re*uired

    3ffect coolant spillage floor 

    Coning machine separate coolant used

    onthly coolant oil consumption 2$$ -ts

    16

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    +.+ I"5r!8% 5as%

    In the improve phase! first make some improvements based on results of the analy,e phase and

    assess the reduction of rim line coolant consumption system. 0ased on current process flow! to

    eliminate the root causes of the problem and improved process flows. So it has decided to

    improve these problems by understanding current process flows and developing improved

     process flows to address the causes of more consumption rate. The coolant recycle unit machine

    as shown in figure =.=.%! magnetic fitter is shown in =.=.#! oil skimmer shown in =.=.< K before

    and after machine set up shown in =.=.=.

    +.+.1 D%8%)!5in# S!)$i!n

    1 coolant recycling unit introduced

     Iron parts removed out purpose magnetic duct collator 

     0ucket #$ micron paper filter unit

     Coolant mi+ed oil removed purpose oil skimmer unit provided

    This unit connects the three machines

    • Coning• Goll former %

    • Goll former #

    i# +.+.16 C!!)an R%(*()% Uni

    17

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    i# +.+.26 Ma#n%i( i)%r Uni

    i# +.+.36 Oi) S@i""%r Uni

    18

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    i# +.+.36 B%'!r% & A'%r C!!)an Tan@ 

    +./ C!nr!) 5as%6 ;arious measures identified to improve the process are documented and

    institutionali,ed. Control phase established to monitor the process of coolant recycle unit.

    +./.1 B%n%'is

    Tan#i9)% B%n%'is

    Gust free

    Cost saving directly

    Gework reduced

    4roductivity improved

    0reakdown occurrence reduced

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    Inan#i9)% B%n%'is

    Operator fatigue reduced

    SOC 3liminated

    Improved Safety

    ?ain Confident to solve problems

    Qob Satisfaction

    20

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    CHAPTER /

    CONCLUSION

    /.1 $$r% S$*

    21

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      REERENCES

     

    %. 1vinash s. 4acha-! 1mol bagesar Taguchi Optimi,ation of 4rocess 4arameters in 8riction‟

    welding of @$@% 1luminium 1lloy and #.1noop C 1! 4awan umar 1pplication of Taguchi ethods and 1'O;1 in ?T19 4rocess‟

    4arameters Optimi,ation for 1luminium 1lloy H$

    H.rishnaiah ! Shahabudeen 4! 1pplied design of e+periments and taguchi methods‟ ! "I 

    learning !vt ltd$)elh #$%