Radheya Machining Ltd. Radheya Machining Ltd.

- TS 16949 Certified Company - TS 16949 Certified Company

 About Us  Fast Facts

Started in 2000, Radheya Group is a fast growing global  Turnover in 2000-01 : 00.95 CR
Engineering organization with business interest ranging from  Turnover in 2011-12 : 120 CR
design to manufacturing of aggregates and systems related to  Compounded Annual Growth Rate – Over 51%
To commercial vehicles, passenger cars, construction, farm
equipments and process equipments.
Our Technocrats Board -
7th National Quality Conclave
Mr. Sanjay A Joshi - Chairman
Mr. Dhananjay A Bhargav – Managing Director
- ‘Improving Quality of Public Services: The Role of Public & Private Sector Mr. Santosh A Joshi - Director

A National Winner Case Study Presentation for  Vision

 Products
To be World-Class Auto-component supplier
D L Shah Award on Economics of Quality – “Quality Council of India” & to become First Choice of the Customers. Engine Gears Sprockets

Category C1 - Micro, Small & Medium Scale Units – Manufacturing Sector  Mission Transmission Gears Tonner Rings
Planetary Gear Assembly Synchro Sleeves
We believe in Appropriate Technology, Excellent Engineering
A Project
Practices & committed for Continuous Improvement by Human
Participation. We would like to contribute in New Development
‘ To Eliminate Noise in Transmission Box During Engine Testing’ programmes of our Customers to face the
challenges.

Radheya Machining Ltd. Radheya Machining Ltd.

- TS 16949 Certified Company - TS 16949 Certified Company

 Customers, Quality Systems & Awards
Valuable Customers
Quality Certifications
 ISO 9001:2000 Certified by UL (2002)
 L-III Supplier Status from M & M FES (2004)
 Deming Supplier for M & M FES (2004)
 TS-16949 Certified by BSI (2006)
Winning Awards
Best Industry Award in Pune for 2007 By
Hon. Dy. C.M.- Maha.- Mr. Ajit Pawar
Bharat Ratna JRD Tata –
Udyog Bhushan Award 2009-10
“Panchratna” award in Forging
Commodity from M & M–FES (2010-11)
Runner Up Prize in Productivity
Improvement Case Study by
IIIE- 2010-11
1st
Prize in Productivity
Improvement Case Study by IIIE-
2011-12
 Customer Quality Focus -
Organizational Approach Quality Culture
 Set Process as per Defined Parameters & Measures by
 APQP- Advance Product Quality Planning
Settings right at 1st Time.
-Using APQP Technique to develop New Product within time
bound program.  Utilize only 40% of Tolerance during Process.
 FMEA – Failure Mode Effect Analysis  Monitor Process through control plans, run charts &
statistical process control.
- Applying Failure Mode Effect Analysis technique to ensure
establish of Defect free Processes  Process & Product Audit at pre-decided frequency.
 PPAP – Product Part Approval Process
 Establish Fool Proof Poka-Yoke wherever possible.
-Establish Manufacturing Process to meet customers
expectations in terms of cost, quality & delivery consistently.
 Final Inspection – within 70% of drawing tolerance
 CFT – Cross Functional Team  Action on Non-Confirming Products by using
techniques- Why-Why analysis & Fish Bone Diagram
- Work with CFT to establish process to meet customer
expectations within time bound program.

Radheya Machining Ltd. Radheya Machining Ltd.

- TS 16949 Certified Company - TS 16949 Certified Company

 Our Project Team -

 Problem Selection is based on Customer feedback
ASHOK SATHE
Team Leader Diagnostics Approach - Pareto Diagram based on Component defects & its Severity Index - FY11Q4
1000 100.0
We have selected Counter Shaft Gear
900
based on severity index for further
DHANAWADE R N SANDIP KHEDKAR investigation.
Team 800 80.0
Production Maintenance 700
Member
M b
600 60.0
Severity Value

500
DEEPAK MORE Shukla S D %
400 40.0
Mfg. Engg. MIS 300

200 20.0

100

0 0.0
Rear Tonner

Idler gear

Pinion Crank

Clutch Hub (1-2)

Counter shaft V4

Gear Cam Shaft

Oil Pump Gear

Companion

Mentor
flange
Wheel

Facilitator Severity Value is defined as Product

shaft
NGT

of Severity Index of the component

- Pramod Mane -Mohan Rangnathan from Final Functional Importance &
No of Defective Component Components
General Manager GM – Quality Assurance

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 Radheya Machining Ltd. Radheya Machining Ltd.
- TS 16949 Certified Company - TS 16949 Certified Company

 Diagnostics Approach for Problem Selection  Diagnostics Approach for Problem Selection
Pareto Diagram based on No.of Defects in Counter Shaft Gear
Background
10 100
PROBLEM :: We have selected Teeth
Damage of countershaft gear as the  Counter shaft Gear (CSG) is one of the components, we
8 80
defect for further investigation and manufacture and supply to automobile OEM’s.
study
study.
6 60

 CSG. Is used in Transmission Gear Box as a Critical

No of Components

4 40 Transmission Component
%

2 20  Quality of CSG plays an important role in Power

Transmission from engine to wheels leading to fuel
0 0 economy & passenger comfort.

Spline Relation
Forging Defects

Bearing Face Not

Teeth Damage

Not Ok
Clean

Defects Type

Radheya Machining Ltd. Radheya Machining Ltd.

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Problem Definition  Qualitative & Quantitative Analysis of Problem - A PROCESS APPROACH

Counter Gear Shaft used in Transmission having Mfg. Audit of 24 Steps Receipt
Five Integral Gears i.e, - Forging Facing Preturning Preturning
Receipt Centering -I - II

Gear 1 - Splines 22Teeth,  Verification of WIP at each stage.

 Dent Mark observed on few components Spline Face CNC CNC Turn -
Rolling Milling Turn - II I
Gear 2 - Gears of 12T at each stage up to Hobbibg 12T.
 Further analysis revealed - 21.36% of the
Gear 3 - Gear of 23T Hobbing Shaping Hobbing Hobbing
components only had the dent marks. 12T 23T 29T 36T
Gear 4 - Gear of 29T  Further detail investigation, point of
generation for dent mark observed after Shaving Shaving Shaving 12T Teeth
Gear 5 - Gear of 36T 29T 23T Chamfer
Face Milling operation.
 Dent Mark was not observed prior to Face
Dent Mark Observed on the Gear 2, Gear Tip Diameter Shaving Heat Grinding ø Grinding ø
Milling operation. 36T Treatment 25 25
of 12 Teeth, Creating Gear Noise during Testing.
Hence, it was concluded that point of
Generation of Dent was during Face Milling Oiling & Final Washing Grinding ø
Operation. Packing Inspection 20

Dispatch

Radheya Machining Ltd. Radheya Machining Ltd.

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 Industrial Engineering Tool Used – Method Study  Process Analyzed

Method Study – Steps : S>>R>>E>>D>>D>>I>>M Method Study – 1 & 2 : Select & Record

1. Picks the component from Input Tray.

1. Select : The Method
2. Load in Milling Fixture.
2 Record
2. : The Elements
Elements.
3. Clamps the Top Jaw.
3. Examine Criticality : The elements.
4. Clamps the Bottom Jaw.
4. Develop : Improved the method - Elements
5. Define : Improved the method – Elements 5. Starts Milling Operation

6. Implement : Improved method. 6. Ends of Milling Operation.

7. Maintain : The improved Method. 7. De-clamps the Jaws.

8. Inspect the component Dimensionally.

9. Put the component in Out Tray.

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 Radheya Machining Ltd. Radheya Machining Ltd.
- TS 16949 Certified Company - TS 16949 Certified Company

 Step 3 – Examine criticality : Why Why Analysis  Steps 4 , 5, 6 & 7 – Define, Develop, Implement & Maintain : Fixture Improved

Problem - Noise in Engine.

WHY – Dent Marks on Gear 2 - 12Teeth Gear Tip Diameter 1. Picks the component from Input Tray.

2. Load in Milling Fixture.

WHY – Jaw Impression on Finish Turned Dia. Of Gear 2 during Flat Milling Operation
3. Clamps the Top Jaw on Non Gear Dia.

WHY – Wrong Location of Top Clamping Jaws 4. Clamps the Bottom Jaw.

5. Starts Milling Operation

WHY – Fixture Design in Adequate
6. Ends of Milling Operation.

7. De-clamps the Jaws.

Fixture
Design 8. Inspect the component Dimensionally Position of Top Clamping
Needs to be & Visually also if dent any Jaw Shifted to Non Geared ,
Improved Non Mating Link Diameter.
9. Put the component in Out Tray.

Radheya Machining Ltd. Radheya Machining Ltd.

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Comparison between Old & New Methods  Improved Operation

Before After .

After Implementation of Improved

Operation, Noise in Transmission
Box has been 100% Eliminated

Clamping of Top Jaw on Position of Top Clamping

12 Teeth Pre Turned Mating Jaw Shifted to Non Geared ,
Gear Diameter. Non Mating Link Diameter.

Radheya Machining Ltd. Radheya Machining Ltd.

- TS 16949 Certified Company - TS 16949 Certified Company

 Economic Benefits -  Economic Benefits - Tangible

Productivity Quality Cost Saving – Annualized

10
Daily Dispatch Qty – 300 Nos. A. Internal Cost
9
Rectification – 21% i.e, 63 Nos. 8
A1 – Annual Rectification Cost – Rs. 236,250 A3 – Reduction in Inventory Carrying Cost
No. of Complaints

Rectification Time – 6mins/component. 7

Rectification Cost – Rs. 1000 / Shift 8Hrs Batch Size in Quantity – 320
- Incremental Inspection Time (2mins) 6 No. of batches / Year – 300
Rectification Cost – Rs. 125 / Hr
- Remove dents by oilstone (3mins) 5 Total Rectification Cost – Rs. 787.50 / Day Manufacturing Value in Rupees – 1104
4 Total Rectification Cost/Day – Rs. 787.50 Original Through Put Time (TPT) in days –3
- Re-Inspection Time (1min)
( 6.3 Hrs (378min/60) x Rs. 125 = Rs. 787.5) New Through Put time (TPT) in days –2
3 2 Time save in Through put time in Days –1
2 1 A2 – Annual Cost Involved due to Rejection- Rs. 3,312,000 Bank Interest rate on working capital / Annum in % - 14.5
1 Rejection during rectification (3.3% of Daily Disp.Qty) – 10
0 0 0 0 0 0 0 0 Manufacturing Cost in Rupees / Component – 1104
Cost saving during to Inventory carrying - Rs. 42,103
i,e. - No.of Batches/year *(Batch Size*Mfg value)*
0 (Original TPT-New TPT)*(Bank Interest Rate on
No. of Working Days / Annum - 300
Mar- Apr- May- Jun- Jul- Aug- Sep- Oct- Nov- Dec- working capital/Annum)
11 11 11 11 11 11 11 11 11 11
Total Internal Cost (A1+A2+A3) – Rs. 3,590,353
Total Time Saving – 378 mins Zero Customer Complaint Since May 2011

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 Radheya Machining Ltd. Radheya Machining Ltd.
- TS 16949 Certified Company - TS 16949 Certified Company

 Economic Benefits - Tangible  Economic Benefits – Non Tangible

Cost Saving – Annualized Delivery

B. External Cost C. Disposal Cost Delivery became Faster due to Elimination of Rectification Time

Annual Managerial Cost – Rs.1,64,000/- apx. Annual Disposal Cost–Rs. 21,600

Total Managerial Cost – Rs. 20,000/- apx. Safety

Total No. of Comp. Disposed – 16Nos
Managerial Cost – Rs. 5000 apx. / Visit
Cost of Component – Rs. 1350/-
The Safety of Operator/Inspector Improved due to Mental Stability
No of Visits (in 3months) – 4 Visits

Rectification Cost at Customer End – Rs. 21,000/-

Rectification Time – Rs. 3000 apx./Visit Morale
(Salary, O.T., Traveling & Incidental etc)
No of Visits (in 3months) – 7 Visits
 Confidence towards Problem Solving Increased
 Team spirit has gone up.
Total Cost Saving Annualized (A+B+C) – Rs. 3,775,953 Apx  Sense of Belongingness towards company has gone up.

COPQ – 3.1 ( % of Total Cost (A+B+C) / Sale Value Annum

Radheya Machining Ltd. Radheya Machining Ltd.

- TS 16949 Certified Company - TS 16949 Certified Company

 Sustainability  Applicability- Better Material Handling & Storage

Process Audit
 Ensuring Working of Fixture through S.O.P.
(Standard Operating Procedure)

Quality Audit
 Added this check point in Final
Quality Plan
Before After

Radheya Machining Ltd. Radheya Machining Ltd.

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 Project – Sub Shaft

 Lesson Learnt by CFT ( Cross Functional Team )

Dummy Piece Alignment

with center
support
Before I.D. - 2 Spline PCD I.D. - 1 After
While developing process for any
During I.D. Hard Turning Process, Internal Spline PCD to
new transmission component,
I.D. concentricity required 0.02mm could not be
clamping shall be given enough
maintained due to - misalignment during clamping Machining after component alignment.
importance
Production Per Day : 200 Nos.
Step 1 – Dummy Piece hold between component & Tail stock center.
Component Produced : 1075 Nos.
Step 2 – Center support activated, component aligned & clamped.
Relation gauge Not qualifying - 260 Nos.
Step 3 – Center support de-activated & dummy piece removed.
PPM - 2,41,860 Step 4 – I.D. Hard Turning Process completed & Inspected.

Annual Production Plan – 60,000 Nos. PPM - Zero

Annualized Cost Saving – Rs.33 Lacs Apx-

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 Radheya Machining Ltd. Radheya Machining Ltd.
- TS 16949 Certified Company - TS 16949 Certified Company

 Company Wide Quality Culture

 Total Economic Benefits due to Quality Improvement

Kaizens
Rs. 85.42 Lacs apx
Some of Kaizen’s under our cost saving program
- Amounts to Rs. 14.67 Lacs

Radheya Machining Ltd. Radheya Machining Ltd.

- TS 16949 Certified Company - TS 16949 Certified Company

 Group Activities – 2011-12

 No of Persons Participated – 128/300 (48%).

 No of Group Activities Completed – 38 i,e. more than 3 per month.

 Value saved – over 90 Lacs.

Any questions ?
 Group Activities – 2012-13

 To Double the above rate.

Team Radheya