23-09-2014, 04:44 PM
ABSTRACT NAME OF THE PROJECT- Reduction of Bonding Problem from 6.85 % to 2% To analyze a process in order to monitor, control, and improve it. The objective is to have a stable, consistent process that produces the fewest defects possible. To control variation so as to avoid product defects. Improve the quality because quality is the degree to which products or services meet the needs of customers. Common objectives for quality professionals include reducing defect rates, Manufacturing products within specifications, and standardizing delivery time. Our aim is to minimize the bonding problem by resolving all the points which were creating problems in the machine line. Important steps on which improvement was made are 1. Baking Temp not as per standard (too high/low). 2. Moulding m/c Temp (too high/low). 3. Rubber Expired. 4. Metal Inserts Expired. 5. Unskilled Operator. 6. Metal Insert thickness on higher end. 7. Vacuum problem in Moulding machine. 8. Mould closing speed not as per standard. 9. Problem with parallelism/bend mould plate A proper Design solutio
PROJECT REPORT
Reduction of Bonding Problem from 6.85 % to 2%
Team.
Varun Misra (Guide)
Divjot Singh (Trainee.)
MAIN TEXT
Project Goal:-
To eliminate Bonding problem in all Tenneco products and to reduce rejection level from 6.85 %to 2% .
Time Goal:
3 months(1 Aug 2013 to 29 Nov 2013) with 100% members’ attendance.
Achievements:-
Ø 6.85% rejection reduced to 2% .
Ø Appreciation from customers for TQM approaches & better ranking in Customer audit.
Ø Getting active participation by workers in improvement activities.
PROJECT DESIGN & METHODOLOGY
The basic elements who constitute the Quality projects are Coordinator, Team leader, Associate Members. All members met at the defined frequency with 100 % attendance as per the plan. Coordinator & facilitator were responsible for the coordinating & directing the Quality related activities inside the organization.
Data Analysis:-
Tools which are used to identify & analyze the problems are given below
Brain Storming Collection of data Flow Diagrams Cause & effect diagram Pareto Diagram Histograms
Results :-
Rejection level at final stage came down to less than 2% from 6.85%. Better Quality Products. Better ranking in customer audit. Improved employee’s morale through their participation & involvement in problem solving.
HIGH LEVEL FLOW DIAGRAM
Metal inserts issuance to MTP
Rubber issuance to Mixing
Pareto Analysis
After Pareto analysis, we found major contribution was of Bonding Failure and Tear problem. Therefore, we took this project on Bonding Failure problem, as it was a critical parameter for our product. Any Bonding Failure product to customer is a sure complaint with heavy warranty claim and loss of customer confidence.
Brainstorming
Then we did brainstorming with all team members, operators, supervisors and Engineers to identify the probable root cause.
These were major findings in brainstorming for Bonding problem:-
1. Baking Temp not as per standard (too high/low).
2. Moulding m/c Temp (too high/low).
3. Rubber Expired.
4. Metal Inserts Expired.
5. Unskilled Operator.
6. Metal Insert thickness on higher end.
7. Vacuum problem in Moulding machine.
8. Mould closing speed not as per standard.
9. Problem with parallelism/bend mould plate
Fish Bone Diagram :-
Cause and effect analysis
Major Causes
1) Baking temperature too high.
2) Machine temperature too high.
3) Vacuum Problem.
Minor Causes
1) Metal insert thickness on higher end.
2) Expired raw material.
3) Oily/Dirty/Dropped Metal Inserts.
4) Unskilled Operator.
5) Operator Not following SOP.
6) Phosphate method not ok.
7) Loading/Unloading of moulding operator slow.
8) Loading Metal inserts without gloves.
9) Parallelism problem.
10) Mould Plate bend.
Testing of theories
Major Cause 1:- Baking Temp at higher end
Ø Took trial with baking temperature at higher end but bonding found ok.
Ø Rej-0% for Bonding Problem.
Major Cause 2:- Moulding m/c Temp at higher end (210°C)
Ø Trial Taken at 210°C and found 9% for Bonding Problem.
Major Cause 3:- Vacuum Problem
Trial taken at 0 vacuum on the moulding machine.
Rej due to bonding failure- 0%
Total rej (process defects)- 15%
Testing of theories
Minor Cause 1:- Metal insert thickness on higher end
Metal inserts taken from incoming store 20 inserts/vendor.
Total vendor- 3.
Specification :- 1.02 to 1.12 mm
Observed Reading from, Vendor 1 - 1.065 ~ 1.075.
Observed Reading from, Vendor 2 - 1.069 ~ 1.084
Observed Reading from, Vendor 3 - 1.061 ~ 1.076.
Result:- Thickness found near to mean, also compared with parent company’s data but no major dimension variation found.
Minor Cause 2:- Expired raw material.
Trial taken with Expired Rubber, still bonding problem was not observed, but flow problems found on the product.
Rejection- 12.95%
Trial taken with Expired Metal Inserts, bonding problem observed
(Rejection- 90%) total trial parts rejected.
Checked all the raw material available on line and found Metal Inserts & Rubber shelf life within specification.
Also checked previous history of one month & found both the raw material shelf life was in specification (checked with the help of relevant documents for eg Route card, Hold Card, and different types of checksheets.
Minor Cause 3:- Oily/Dirty/Dropped Metal Inserts.
Trial taken with oily gloves (5shots) -Status-Ok.
Trial taken with dirty gloves (used - 5 shots) - Status-Ok.
Trial taken with dropped metal inserts (5 shots) -Status-Ok.
Minor Cause 4:- Unskilled Operator.
Trials taken with 3 new operators directly asked to work on machine just after explaining the whole activities, and showing them the various steps being performed by already trained operators. Two shots per operator monitored for bonding test.
Bonding rejection 0%, but other problems were observed like higher cycle time & undercured parts.
Minor Cause 5:- Operator not following SOP.
Told operator not to follow the SOP as prescribed in the Work Instructions for eg loading & unloading of parts was not in sequence.
Result