PRESENTATION ON

“ INDUSTRIAL IN-PLANT TRAINING ”

PRESENTED BY
Hemant wani
Guided By
Prof. Nilesh Bulki
About Bosch
 The Bosch Group is a leading global supplier of technology and services.
 350 subsidiaries and regional companies in over 50 countries and sales and
service partners in roughly 150 countries worldwide.
 The Bosch Group operates in India through six companies:
I. Bosch Limited,
II. Bosch Chassis Systems India Limited,
III. Bosch Rexroth India Limited,
IV. Robert Bosch Engineering and Business Solutions Limited,
V. Bosch Automotive Electronics India Pvt Ltd,
VI. Bosch Electrical Drives India Pvt Ltd.
Bosch Chassis Systems India Limited

 Bosch Chassis Systems India Limited develops and manufactures innovative

braking system components and vehicle safety systems for the automotive
industry.
Areas of operation – Product portfolio.
 Brake Booster, Tandem Master Cylinder (TMC) and Proportioning Valves
 Antilock Braking System (ABS) and Electronic Stability Program (ESP®)
 Passive Safety Systems like Airbag Electronic Control Units (ECUs)
 Driver Assistance Systems
 Solutions for Electric and Hybrid Electric Vehicles
MY WORK
 14Q principle Implementation .
 Contamination study in assembly line (Making WI and
Check sheet) successfully Implement on line.
 Working on 8D Process.
 FMEA and Control plan.
14-QUALITY PRINCIPLES
 Principle 1 – Stop.
 Principle 2 – Andon Cord,

 Principle 3 – HSE & 5S.

 Principle 4 – Process Parameters

 Principle 5 – Measuring And Test Equipment’s.

 Principle 6 – Check The Checker.

 Principle 7 – Maintenance Standard.

 Principle 8 – Tool Service Life.

 Principle 9 – Restart.

 Principle 10 – Labelling.

 Principle 11 – Rework

 Principle 12 – Parts On Floor.

 Principle 13 – Removal and Assembly of Correct Parts.

 Principle 14 – Remaining Items.

 Principle 1: STOP
 Customer claims are visualized and stop sign is placed at the station
or near to the process or area where the problem occurred.
 The application of a systematic Problem solving method is
mandatory.
Principle 2: Andon Cord
 Deviations could be exceeding agreed process tolerances & could
also involve more subjective observations .
 A quick reaction system must be in place, which allows the team
member to stop the process (e.g. stop the m/c & inform the
Supervisor).
Principle 3: HSC
 Manufacturing and testing instructions are clearly displayed at each station and are
followed.
 Health and safety checks are done in strict accordance with the regulations.
Principle 4: Process Parameter
 All process parameters be checked on basis of the control plan.
 The specifications of the control plan be checked, including the setting parameters on
the station, process confirmation (e.g. checklists for start-up, for settings…)?

Principle 5: Measuring and Test Equipment

 All measuring and test equipment to be used defined in the control
plan.
 All testing devices are calibrated and labeled accordingly.
 Identification and status of inspection tools must be visible
Principle 6: Check The Checker
 Check the checker method is applied to ensure the checker’s capability.

 The stability of processes designed to identify failures (cameras, sensor-

based measurement, testing routines) must be checked according to the

standard and must be capable.
Principle 7: Maintenance Standard
 A maintenance standard for each station is installed and applied .

 the four-pillar TPM model, particularly the autonomous and preventative

maintenance, instituted at every station/production line

Principle 8: Tool Service Life
 Tool life is defined for all tools; the current status must be visible;
quality assessment must take place after tool change
 Tool life is being tracked continuously
Principle 9: Restart
 Restart of machinery and equipment after stoppages is clearly

defined
Principle 10: Labelling
 Parts and boxes are marked according to a standard
 Components, products and containers (e.g. blisters, boxes,

packaging) are labeled according to a set standard.

Principle 11: Rework.
 At RBIC / ChkP rework is not applicable

Principle 12: Parts on Floor

 Parts which dropped on the floor must be scrapped
Principle 13: Removal and Assembly of Correct Parts
 All material is in the defined place. First-in-first-out
principle must be observed
 At the time of assembly, is only the correct
part/component available to the associate.
 All material is in the defined place. First-in-first-out

principle must be observed.

Principle 14: Remaining Items
 Handling of leftover parts is clearly defined .
 Remaining quantities clearly labeled and stored securely.

 Maximum storage times must be carefully maintained.

As per all above principles, we started audit with MSV Department Line.
Gap analysis
STUDY OF CONTAMINATION IN ASSEMBLY LINE

 For controlling contamination on assembly lines, preparing cleaning

instruction sheet
 Display on work station for respective operation with the help of this
sheet line operator and line supervisor is cleaning work station as per
shown this sheet
 No positions: Opn- 15 Place: ChkP-MSV
Passenger-Plunger sub assembly The Plan Maintenance, Inspection , Cleaning,
Department: MSV-MFO Data: week 50

Monday Tuesday Wednesday Thursday Friday Saturday

kind of Time Freque Auxiliary Materials ,
Sr.No Who Description of activities
activities min ncy Spare Parts
I II III I II III I II III I II III I II III I II III

Plunger sub assembly fixture - Clean it by lint free

1. O 1.5 Z
blue cotton and vaccum cleaner
Standard work in process - Clean it by lint free
2. O 1 Z
blue cotton
Retainer & Plunger sub assembly table - Clean it
4. O 1
by lint free blue cotton
Z

5. O 1 Straight pin tray - Clean it by lint free blue cotton D

6. O 1 Child parts tray - Clean it by lint free blue cotton D

Plunger tray - Clean it by lint free blue cotton and
7. O 1 D
vaccum cleaner
Note : 1) Use air gun outside the assembly point
2)Clean fixed tray before loading new material
- control - visually - manually - clean by brush

O - Operator MFO
-lubrication Lean free cotton Portable Vacuum cleaner S - Supervoiser
M - Maintanence
Z - Per Shift , D - daily, T- weekly, 2T - Every 2 Weeks, M - Monthly,
Q - quarterly, HY - Half-Yearly, Y - Yearly, TPM
Conclusion
 The 14Q principle is very effective method to reduce & eliminate all the
errors & gaps which continuously occurs on production lines.by using
these principles we have conducted audit on all the production lines on
shop floor.
 While conducting audits it’s very challenging to find all the
small gaps & errors in every machine & the process. also to take
the target dates, root cause & corrective action over all the gaps
found. We made the open point lists to observe this gaps as per
PDCA chart.
REFERENCES
 [1]B. Zuender, "bosch.zuender@bosch.com," [Online].
Available: http://bzo.bosch.com/. [Accessed 12 MAY 2016].

 [2] RBIC, "Q-Basic@bosch," [Online]. Available:

http://connect.bosch.com/service