AK KIT ASSEMBLY PPM REDUCTION

2015 Tecumseh Products Company

 PPM Reduction Road Map

Current
2388 PPM

Phase I
Oct16
Target-1194 PPM

AK KIT ASSEMBLY Target

Phase II
31st Dec Actions
Target-597 PPM

Phase III
Mar17
Target-358 PPM

TARGET 100
PPM

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 Internal PPM Reduction Road Map

Current
675112 PPM

Phase I
Target- 254418 PPM

Phase II
Target- 172451 PPM

Phase II
Target- 91122 PPM

TARGET
47477 PPM
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 Current PPM analysis

Current rejection PPM at customer

Defects Qty PPM
Tight 48 678.38
ZE Cylinder Head 33 466.39
Taping 23 325.06
piSTON Hit 22 310.92
Foreign Material 16 226.12
Crank shaft 10 141.33
Score Rod 9 127.19
LB 4 56.53
CC Problem 2 28.26
Tube Leak 1 14.13
CS Under size 1 14.13
Total 169 2388.49

Out of all the rejections at customer 60% of rejections are due to Tight,
ZE cylinder head lock pin hole out, Tapping defects

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 AK KIT defect Trend

800 120%

700 678
100%
600
80%
500 466

400 60%
325 311
300
226 40%
200 141 PPM Cumilative PPM
127
20%
100 57
28 14 14
0 0%

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 Phase I

Target- 1194PPM

Actions Initiated:

Target
SNO Defect Action Initated Resp Date
100% freeness check at Kit testing & manual checking prior to
packing.
1 Tight Crank Shaft 100% Oil hole Jet cleaning. To avoid Contamination. Phani Immediate

ZE cylinder head Lock pin Will work with SQD to eliminate this defect as this is a supplier
2 hole out defect SQD/Phani TBD

3 Tapping 100% checking being done before assembly with help of gauge Phani Immediate
Already
Initiated
4 Crank Shaft 100% Visual inspection of dents on Crank Shaft ,ConRod,OBB phani

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 Phase I
SN
O Defect RootCause Action Initated Resp Target Date
100% freeness check at Kit testing & manual
1 Tight OBB Perpendicularity out of spec checking prior to packing Phani Immediate
Gangad
100% Squareness Checking Before Imeco har/viv
Crank Case OBB Squareness Washing ek Immediate
Start of the shift and every 3 hrs Operator is
inspecting OBB Alignment and Maintaining Maintaining
OBB Alignment out of spec record. phani Record
Position of OBB Top Bush.
Special Tools initiated for removing burs in oil
Con Rod Oil hole bur hole. Moosa Maintaining
Crank Shaft Short End damage
Piston Damages on OD while
Washing,handling Before Washing
Vivek/G
Shifting of Crank case cylinder angadh
head Holes 100% Checking ar
Wrong selection of Gasket.
Double Suction Valve With Less
gasket .
Shifting of OBB Holes

ZE cylinder
head Lock pin Will work with SQD to eliminate this defect as SQD/Ph
2 hole out this is a supplier defect ani
100% checking being done before assembly with help of
3 Tapping guage Phani 7
 Phase II

Target- 597 PPM

Actions Initiated:

Target
SNO Defect Action Initated Resp Date
During Phase-I we Will collect data at all Stages Stiff Issue is arising.
1 Tight We will take Counter Actions at all Stages where stiff issue is arising. phani

Trolleys planned instead of nylon trays at soaking area to avoid foreign

2 Foreign Material
material in crank cases Phani 20 Oct 16