Six Sigma Project

Indian Statistical
Institute, Pune 6s

Increase First Time Right Ratio (FTR) of Axle Assembly

(from Avg 47% to Avg.98% )

Submitted by : Atul P. Daptardar

Project Guide : Prof. Subrata Rath

Date : 13-Mar-2013
 About Product : Portal Axle
Indian Statistical
Institute, Pune
6s
About Organization
World leader in the supply of axles;
driveshaft; off-highway transmissions;
sealing and thermal-management products;
and genuine service parts.

Integrated machining & assembly site

About Product COE for Steer axles and compact AG tractor

Portal Axle: Compared to normal Axle, portal
axles enable the vehicle to gain a higher
ground clearance, as both the axle tube and
differential casing are tucked up higher under
the vehicle.
Drive axles up to 100 hp to support
domestic market & export
COE for components subassembly
(differential assemblies, planetary carriers).

Application : Tractor Pune Plant Capacity: Steer axles - 60,000 nos.

Drive axles - 15,000 nos.
Capacity : 25 - 45 HP Machining - 50,000 hrs.
 Define
Business Level Dashboard
Indian Statistical
6s
Institute, Pune

Vision Strategies Strategic Business Measures Unit Monitoring Responsibility

Objectives of Frequency
Meas
ure
Increasing Achieve FTR 98% on FTR % % Daily ME- PRA- QA
revenue & axle assembly
Productivity
by exporting Rework % to be Rework % % Daily PRA-QA
Drive axles reduced
with minimum Reduce scrap as % of Scrap cost INR Monthly PRA-QA
or zero in sales cost dut to
process rework
rejection.
Production Plan Vs % plan Vs % Daily PRA
Actual Actual

Rework cost Rework INR Monthly PRA

cost

Inprocess Inventory Inventory INR Monthly PRA

Cost cost

ME : Manufacturing Engineering; PRA : Production Assembly; QA : Quality Assurance

 Define
Project Hopper
Indian Statistical
Institute, Pune 6s
 R-DMAIC
Project Phases
Indian Statistical
Institute, Pune
6s
Increasing First Time Right Ratio of Axle
Date Initiated 5- Dec -2012 Project Name:
Assembly from 47% to 98%

Key Steps: 1 5-Dec-2012 2 15- Dec - 2012 3 2- Jan -2013 4 25- Feb 2013 5 On going

Define Measure Analyze Improve Control

Step A: Identify Project Step 1: Select CTQ Step 4: Establish Process Step 7: Screen Potential Step 10: Define & Validate the
CTQs Characteristics Capability Causes Measurement System
on Xs

Step B: Develop Team Step 2: Define Step 5: Define Step 8: Discover Variable Step 11: Determine Process
Charter Performance Performance Relationships Capability
Standards Objectives

Step C: Define Process Step 3: Measurement Step 6: Identify Variation Step 9: Establish Step 12: Implement Process
Map System Sources) Operating Control
Analysis Tolerances

Overall Project Completion Percentage 100%

Key Deliverables
Required
• List of Project CTQs
• Team Charter
• High Level Process Map
(COPIS)
Tools That May Help
• Project Risk Assessment
• Stakeholder Analysis
• High Level Project Plan
• In Frame/Out of Frame
• Customer Survey
Methods (focus groups,
interviews, etc.)
• Elevator Speech
Required
• Data Collection Plan
• CTQ Worksheet:
Operational definition,
Specification limits, target,
defect definition for Project
Y(s)
• Measurement System
Analysis
Tools That May Help
• QFD
• Gage R&R/Attribute R&R
• Detailed Process Map
• FMEA
• Pareto Analysis
Required Required Required
• Baseline of Current Process • List of Vital Few Xs • MSA Results on Xs
Performance • Transfer Function(s) • Post Improvement
• Graphical analysis of output • Optimal Settings for Xs Capability
(Y)
• Confirmation • Statistical Confirmation
• Statistical Goal Statement
for Project Runs/Results of Improvements
• List of Statistically • Tolerances on Vital Few • Process Control Plan
Significant Xs Xs • Process Owner Signoff
Tools That May Help Tools That May Help Tools That May Help
• Six Sigma Process &
• Design of Experiments • Control Charts
Product Reports • New Process Maps • Hypothesis Testing
• Benchmarking
• FMEA on new process • CAP Plan
• Fishbone Diagram
• Process Modeling • Documentation/SOP
• Hypothesis Testing
• Regression Analysis • Brainstorming
 Define
Project Charter
Indian Statistical
Institute, Pune
6s
 Define
Project CTQ Tree
Indian Statistical
Institute, Pune
6s
 Project CTQ’s Define
Indian Statistical
Institute, Pune
Step A
 Business Case Define
Indian Statistical Step B
Institute, Pune
Benifits Project Scope

1.Improved Quality of product. Process Starts With: Rejection Data collection

Process Ends With: Implementation Of Corrective & Preventative
2.Avoidance of potential field failures Actions & monitoring their effectiveness

3.Reduction in rework cost Inscope : Axle Assembly at Plant

Outscope : None
4.Meet customer delivery schedule
Constraints: None
5.Reduction in internal rejection / scrap cost Process Impacted: Axle assembly process, Housing casting
process
6.Customer satisfaction
Business Y Impacted: FTR of Axle assembly
Team Roles
Problem Statement:
FTR of Axle assembly is 43% on an average per day for Champion: Plant Head
20days during 1st Nov 12 to 31st Nov 12 Black Belt: Atul Daptardar
Master Black Belt / Coach: Quality Head
Quality Leader: Quality Head
Goal Statement & Estimated Benefit: Process Owner: Production Manager
Team Members: GBs and YBs
To Achieve 98% FTR for Axle assembly by Jan-13

Project Timeline
Financial Impact: Customer Want Date: 01/03/2013
2012-13 Estimate Annual Estimate
Revenue Enhancement Rs --- Rs. 660 lakh STEP (**) Estmtd Date Actual Signoff Date
Expense Reduction Rs. 12 lakh Rs. 24 lakh Define 10/12/13 10/12/13
Loss Reduction Rs. 52.5 lakh Rs. 105 lakh Measure 18/12/13 10/12/13
Cost Avoidance Not known yet Analyze 15/01/13 10/12/13
Total Rs. 64.5 lakh Rs. 789 Lakh Improve 25/01/13 25/01/13
Control 30/01/13 30/01/13
 Team Charter Define
Indian Statistical Step B
Institute, Pune

Resource Plan General Information Tollgate Review Dates

Project Lead (GB/BB): Atul Daptardar Tollgate Date Signoff
Project Coach (BB/MBB): Quality Head (xx/xx/xx)

Project Champion: Plant Head Big Y: Define 10/12/13 10/12/13

Team Members: MP 1
Measure 18/12/13 18/12/13
MP 2 MP 4
MP 3 Q1 Analyze 15/01/13 18/01/13
HO 1 HO 2
Improve 20/02/13 25/02/13
Increasing First Time Right Ratio of Axle Assembly
from 47% to 98%
Control
Contact Information for Project Lead: 25/02/13 05/03/13
9011046582
atuldaptardar@gmail.com

Project Team Rhythm and Review Rhythm and Review:

On-Track
Daily Off-Track
Meeting Frequency: Meeting Day and Time:
Need Attention
Mandatory Attendees: BB GB YB’s

Optional Attendees:
Champion Coach Functional Manager
 High Level Process Map Define
Indian Statistical Step C
Institute, Pune

C O P I S Key Questions
Customer Output Process Input Supplier
(Use nouns) (Use verbs) (Use nouns) What are the process boundaries?
Start: In coming part Inspection

In coming Part Stop: Axle Dispatch

1
Inspection Engineering
What is included/excluded in the
Drawing scope of this project?
Housing Includes: In-house Manufacturing
2
Machining Process

Excludes: None
Differential What is the Unit, Opportunity,
3
Assembled Assembly Process All Child Part Defect?
OEM & Tested parameters Suppliers % Defects observed at final testing
OK Axle Wheel End Specifications station.
4
Assembly
Has this process map been

5
Axle validated by key people?
Assembly YES.
Operations Process Engineering, QA & Production
Final Testing Instructions
6
& Inspection
Improve FTR % of
7
Packing & Axle assembly
Dispatch process
 Gauge R & R Measure
Indian Statistical
Institute, Pune
Step A

GAUGE R & R STUDY

Reported by : A tul D aptardar
G age name: A IR LE A K TE S TE R Tolerance: P ressure D rop 0.39 P a M A X
D ate of study : 11-12-2013 M isc:

Components of Variation Air leak by Batches

% Contribution 0.32
100 % Study Var
Percent

% Tolerance
0.24
50

0.16
0
Gage R&R Repeat Reprod Part-to-Part 1 2 3
Batches
R Chart by Inspector
Air leak by Inspector
Ajay Bagade Chetan
Sample Range

UCL=0.02288 0.32
0.02
_
0.01 R=0.00889 0.24

0.00 LCL=0
1 2 3 1 2 3 1 2 3 0.16
Batches Ajay Bagade Chetan
Inspector
Xbar Chart by Inspector
Ajay Bagade Chetan Batches * Inspector Interaction
UCL=0.2276
Sample Mean

Inspector
0.25 _
_ Ajay
0.25
Average

X=0.2185 Bagade
0.20 Chetan
0.20
0.15
1 2 3 1 2 3 1 2 3 LCL=0.2094 0.15
Batches 1 2 3
Batches
 Gauge R & R Measure
Indian Statistical Step A
Institute, Pune

 Upper process tolerance limit = 0.39

Source StdDev (SD) (6 * SD) (%SV) (SV/Toler)

Total gage R&R 0.0056557 0.033934 8.46 9.89

Repeatability 0.0056557 0.033934 8.46 9.89

Reproducibility 0.0000000 0.000000 0.00 0.00

Inspector 0.0000000 0.000000 0.00 0.00

 Part-To-Part 0.0666431 0.399859 99.64 116.59

 Total Variation 0.0668826 0.401296 100.00 117.01

 Number of Distinct Categories = 16

CONCLUSION : GAUGE IS ACCEPTABLE AS TOTAL GAUGE R & R IS 8.46 & NDC IS 16

Indian Statistical
Institute, Pune

GAUGE R & R STUDY

Reported by : A tul D aptardar
G age name: A XLE TE S T BE N C H Tolerance: 1.5 M A X
D ate of study : 11-12-2013 M isc:

Components of Variation D spin by Batches

100 % Contribution
% Study Var 0.12
% Tolerance
Percent

50 0.08

0.04
0
Gage R&R Repeat Reprod Part-to-Part 1 2 3
Batches
R Chart by Inspector
D spin by Inspector
Ajay Bagade Chetan
Sample Range

UCL=0.02288
0.02 0.12
_
0.01 R=0.00889
0.08
0.00 LCL=0
1 2 3 1 2 3 1 2 3 0.04
Batches
Ajay Bagade Chetan
Inspector
Xbar Chart by Inspector
Ajay Bagade Chetan Batches * Inspector Interaction
Sample Mean

0.12 Inspector
0.12
_
_
Ajay
UCL=0.09095
Average

Bagade
0.08 X=0.08185
LCL=0.07276 Chetan
0.08
0.04
1 2 3 1 2 3 1 2 3
0.04
Batches 1 2 3
Batches
 Gauge R & R Measure
Indian Statistical Step A
Institute, Pune

Upper process tolerance limit = 1.5 Max.

Source StdDev (SD) (6 * SD) (%SV) (SV/Toler)

 Total Gage R&R 0.00499 0.0299 9.62 4.86

 Repeatability 0.00499 0.0299 11.62 4.86

 Reproducibility 0.00 0.00 0.00 0.00

 Inspector 0.00 0.00 0.00 0.00

 Part-To-Part 0.042 0.256 99.32 41.55

 Total Variation 0.042 0.257 100.00 41.83

 Number of Distinct Categories = 12

CONCLUSION : GAUGE IS ACCEPTABLE AS TOTAL GAUGE R & R IS 9.62 & NDC IS 12

 Baselining & Baselining Process Capability Measure
Indian Statistical Step A
Institute, Pune

Time Series Plot of FTR

52

51

50

49
% FTR

48

47

46

45

44

43
4 7 10 13 16 19
Day

FPY data is collected for 20 days and analysed using time series plot, data does not show
any specific trend, hence this data can be considered as base line data
 Baselining & Baselining Process Capability Measure
Indian Statistical Step B
Institute, Pune

 Process Capability of Air leak test result

Process Capability of Air Leak Test

USL
P rocess D ata W ithin
LS L * O v erall
Target *
USL 39 P otential (Within) C apability
S ample M ean 29.9677 Cp *
S ample N 31 C PL *
S tD ev (Within) 12.5222 C P U 0.24
S tD ev (O v erall) 11.08 C pk 0.24
O v erall C apability
Pp *
PPL *
PPU 0.27
P pk 0.27
C pm *

0 10 20 30 40 50 60
O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance
P P M < LS L * PPM < LS L * P P M < LS L *
P P M > U S L 258064.52 PPM > U S L 235361.71 P P M > U S L 207482.23
P P M Total 258064.52 PPM Total 235361.71 P P M Total 207482.23
 Baselining & Baselining Process Capability Measure
Indian Statistical Step B
Institute, Pune

 Process Capability of End of line Testing – Delta Spin

Process Capability of Delta spin

USL
P rocess D ata W ithin
LS L * Ov erall
Target *
USL 1.2 P otential (Within) C apability
S ample M ean 2.49968 Cp *
S ample N 31 C PL *
S tD ev (Within) 3.47568 C P U -0.12
S tD ev (O v erall) 5.56995 C pk -0.12
O v erall C apability
Pp *
PPL *
PPU -0.08
P pk -0.08
C pm *

-10 -5 0 5 10 15 20
O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance
P P M < LS L * PPM < LS L * P P M < LS L *
P P M > U S L 225806.45 PPM > U S L 645773.48 P P M > U S L 592250.27
P P M Total 225806.45 PPM Total 645773.48 P P M Total 592250.27
 Rejection Data Analyze
Indian Statistical Step A
Institute, Pune

Daily rej.- Check sheet

Sr. Prob. Disc. 3-Dec 4-Dec 5-Dec 6-Dec 7-Dec 9-Dec 10-Dec 11-Dec 12-Dec Total
no. rej.
Face seal
1 leak ll l l ll ll ll llll 15
High Delta
2 Spin ll llll llll llll lll lll lll llll llll 32
Housing
3 leak ll ll ll l lll lll l 14
Welch
4 plug leak l lll ll ll ll l 11
5 Rej. Qty 4 7 10 7 9 8 9 8 10 72
 Parato Analysis of Rejection Data Analyze
Indian Statistical Step A
Institute, Pune

Pareto Chart of Defects Vs frequncy

80

70 100

60
80
50
REJ. QTY.

Percent
60
40

30 40

20
20
10

0 0
Defects Rotation tight Face seal leak W elch plug leak C ov er "O" ring leak
REJ. QTY. 32 15 14 10
Percent 45.1 21.1 19.7 14.1
C um % 45.1 66.2 85.9 100.0
 Identify Variation Sources – Fault Tree Analyze
Indian Statistical Step B
Institute, Pune

01- Rotation Tight : High Delta Spin / High torque to rotate

Gear Mounting
Incorrect shim selection Face Distance of
In correct Pre Knuckle Not Ok
load
Incorrect Mounting
Dimensions Incorrect Spline
length of drop shaft
Re used Shims
Contamination Incorrect Measurement
High Torque by operator
To Rotate Calibration Of
instrument
Measurement
Error
Gauge R & R
In correct Dolly
Excessive
Bearing cup &
friction of In correct alignment of fixture
cone Alignment
Bearing

Lube oil not Dents on the bearing

applied at bearing resting face
race area

01 WHY ? 02 WHY ? 03 WHY ?

 Improvement Actions Improve
Indian Statistical Step B
Institute, Pune

BEFORE AFTER

Incorrect Spline length of Drop Shaft Parts Segregated only OK parts

used for assembly

Supplier: GNA

Root Cause: Between Center centering

groove depth Variation is resulting in
spline length variation

Corrective Actions :

1. Special gauge introduced to check

centering groove depth. Spline length
will be ensured by controlling the center
grove depth

2. 100% inspection will be done for dim.

47.242±0.75 with Go No Gauge instead
PRELOAD VARIATION DUE TO
of sampling
SPLINE LENGTH UNDERSIZE BY 1.5 MM
 Improvement Actions Improve
Indian Statistical Step B
Institute, Pune

BEFORE AFTER

LUBRICATING OIL NOT REACHING AT

RIGHT AREA IN THE BEARING

LUBRICATING OIL APPLIED IN BETWEEN

BEARING RACE WAY WHERE IT IS REQUIRED
 Improvement Actions Improve
Indian Statistical Step B
Institute, Pune

BEFORE AFTER

PRELOAD VARIATION DUE TO REJECT THE USED SHIM FOR

RE-USE OF SHIM FOR PRELOAD SETTING PROPER PRELOAD SETTING
 Improvement Actions Improve
Indian Statistical Step B
Institute, Pune

BEFORE AFTER

EXCESSIVE FLOAT IN THE ASSEMBLY FIXTURE DUE FIXTURE BOLTS ARE TIGHTNED TO ENSURE
TO LOOSE BOLTS CORRECT ASSEMBLY
 Parato Analysis of Rejection Data Analyze
Indian Statistical Step A
Institute, Pune

Pareto Chart of Defects Vs frequncy

80

70 100

60
80
50
REJ. QTY.

Percent
60
40

30 40

20
20
10

0 0
Defects Rotation tight Face seal leak W elch plug leak Housing leak
REJ. QTY. 32 15 14 10
Percent 45.1 21.1 19.7 14.1
Cum % 45.1 66.2 85.9 100.0
 Identify Variation Sources – Fault Tree Analyze
Indian Statistical Step B
Institute, Pune

02 – Face Seal Leakage

Incorrect storage In correct Oil
Face seal
Damage
Improper lubrication

Incorrect Incorrect method of

Mounting oil application
Flatness Not Ok
Leakage
Through Face Calibration Of
Seal instrument
Measurement
Error
Gauge R & R
In correct Packaging

Handling
Damage In correct handling In
Face seal house
resting area
damaged Lube oil not Damaged during
applied at bearing washing process
race area

01 WHY ? 02 WHY ? 03 WHY ?

 Improvement Actions Improve
Indian Statistical Step B
Institute, Pune

BEFORE AFTER
Face seal will
not seat at
correct
position if this
side of dolly is
used

ASSEMBLY FROM CORRECT SIDE TO

FACE SAEL ASSEMBLY FROM WRONG
ENSURE CORRECT ASSEMBLY MISTAKE
SIDE OF THE DOLLY
PROFFING DONE BY REPLACING DOLLY
WITH GROVE ON SINGLE SIDE ONLY
 Improvement Actions Improve
Indian Statistical Step B
Institute, Pune

BEFORE AFTER

Nylon brush
implemented

MS-8 LUB OIL APPLIED BY HAND, RESULTING MS-8 LUB OIL APPLIED BY NYLON BRUSH
IN NON UNIFORM LAYER OF OIL TO ENSURE UNIFORM OIL LAYER
 Parato Analysis of Rejection Data Analyze
Indian Statistical Step A
Institute, Pune

Pareto Chart of Defects Vs frequncy

80

70 100

60
80
50
REJ. QTY.

Percent
60
40

30 40

20
20
10

0 0
Defects Rotation tight Face seal leak W elch plug leak Housing leak
REJ. QTY. 32 15 14 10
Percent 45.1 21.1 19.7 14.1
Cum % 45.1 66.2 85.9 100.0
 Identify Variation Sources – Fault Tree Analyze
Indian Statistical Step B
Institute, Pune

03 – Welch Plug Leakage

Incorrect storage
Welch Plug
Damage
Improper Handling

Incorrect
Mounting
Knuckle ID Not
Leakage Ok
Through Calibration Of
Welch Plug instrument
Measurement
Error Gauge R & R

Non uniform sealant Sealant application

application Process Constraint
Non uniform
sealing
In effective sealing due to
sealing in Metal to metal
contact
01 WHY ? 02 WHY ? 03 WHY ?
 Improvement Actions Improve
Indian Statistical Step B
Institute, Pune

BEFORE AFTER

Rubber
Large Metal To Cladded welch
Metal contact plug used to
Less sealing ensure leak
area proofing.

High rejection in air leakage due to metal to Rubberised welch plug is used to ensure
metal sealing contact and limited sealing the complete sealing area & leak proof
area through special bid. sealing.
 Parato Analysis of Rejection Data Analyze
Indian Statistical Step A
Institute, Pune

Pareto Chart of Defects Vs frequncy

80

70 100

60
80
50
REJ. QTY.

Percent
60
40

30 40

20
20
10

0 0
Defects Rotation tight Face seal leak W elch plug leak Housing leak
REJ. QTY. 32 15 14 10
Percent 45.1 21.1 19.7 14.1
Cum % 45.1 66.2 85.9 100.0
 Identify Variation Sources – Fishbone Diagram Analyze
Indian Statistical Step 6
Institute, Pune

Material

Wrong chemical composition

 Improvement Actions Improve
Indian Statistical Step B
Institute, Pune

BEFORE AFTER
Supplier: Himgiri

Root Cause:
Detection : Air leak testing not available at
supplier’s end.

Occurrence: Shrinkage porosity due to

Sand falling from manual rubbing for
inserting sleeve. This was don due to
unavailability of regular standard sleeve

Corrective Actions :
Detection : Air leak test implemented at
supplier end.

Occurrence: Replaced exothermic sleeve

with spring demeanor eliminating sleeve
requirement in that zone

Air Leakage Observed through Porosity at the trunnion location was

Housing eliminated resulting in leak proof housings
 Process Capability of Delta spin Control
Indian Statistical Step A
Institute, Pune

 Process Capability of End of line Testing – Delta Spin

Process Capability of Delta Spin-After

USL
P rocess D ata W ithin
LS L * Ov erall
Target *
USL 1.2 P otential (Within) C apability
S ample M ean 0.13186 Cp *
S ample N 43 C PL *
S tD ev (Within) 0.084803 C P U 4.20
S tD ev (O v erall) 0.0966894 C pk 4.20
O v erall C apability
Pp *
PPL *
PPU 3.68
P pk 3.68
C pm *

0.0 0.2 0.4 0.6 0.8 1.0 1.2

O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance
P P M < LS L * P P M < LS L * P P M < LS L *
P P M > U S L 0.00 P P M > U S L 0.00 P P M > U S L 0.00
P P M Total 0.00 P P M Total 0.00 P P M Total 0.00
 Process Capability of Air leak Control
Indian Statistical Step A
Institute, Pune

Between/Within Capability of Air Leak

USL
P rocess D ata B/W
LS L * Ov erall
Target *
USL 39 B/W C apability
S ample M ean 11.2333 Cp *
S ample N 30 C PL *
S tD ev (Betw een) 0 C P U 2.33
S tD ev (Within) 3.97792 C pk 2.33
S tD ev (B/W) 3.97792 O v erall C apability
S tD ev (O v erall) 4.03163 Pp *
PPL *
PPU 2.30
P pk 2.30
C pm *

5 10 15 20 25 30 35
O bserv ed P erformance E xp. B/W P erformance E xp. O v erall P erformance
P P M < LS L * P P M < LS L * P P M < LS L *
P P M > U S L 0.00 P P M > U S L 0.00 P P M > U S L 0.00
P P M Total 0.00 P P M Total 0.00 P P M Total 0.00
 Improvement Verification – Control Chart : Before & After Control
Indian Statistical Step B
Institute, Pune

I-MR Chart of FTR % by Month

D ec Jan F eb
U
_ C L=104.11
100 X=97.25
LC L=90.39
80
% FT R

60

40

1 7 13 19 25 31 37 43 49 55
Days O f P r oduction

D ec Jan F eb
16

12
Moving Range

8 U C L=8.43

4 __
M R=2.58
0 LC L=0
1 7 13 19 25 31 37 43 49 55
Days O f P r oduction
Indian Statistical
Control Chart Implementation Control
StepB
Institute, Pune

X- R Chart For Air Leak Testing

20
U C L=18.14
Sample Mean

15
_
_
X=11.37
10

5 LC L=4.60
1 2 3 4 5 6 7 8 9 10
Sample

U C L=17.03
16
Sample Range

12

8 _
R=6.62
4

0 LC L=0
1 2 3 4 5 6 7 8 9 10
Sample
Indian Statistical
Control Chart Implementation Control
Step B
Institute, Pune

X- R Chart for Delta Spin Axle testing

0.24 UB=0.25

0.18
Sample Mean

_
_
X=0.1360
0.12

0.06

LB=0.01
0.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Sample

UCL=0.3126
0.3
Sample Range

0.2

_
R=0.1214
0.1

0.0 LCL=0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Sample

Tests performed with unequal sample sizes

 Update PFMEA
Indian Statistical
Control
Institute, Pune
Step B

PFMEA IS UPDATED
 Update Control Plan
Indian Statistical
Control
Institute, Pune
Step B

CONTROL PLAN IS UPDATED

 Control Summary Control
Indian Statistical
Institute, Pune
Control/Response Plan Highlights Benefits of Project
1. All the improvement actions are validated for
sustenance for consecutive 20 days of acceptable 1.Scrap Cost reduced significantly
level of performance before actual conclusion & 2.Rework Cost Reduced.
final implementation. 3.Better Quality Product, less chance of
Warranty failure or customer complaint.
2. PFMEA & CP are updated. 4.Eliminate production loss due to
rejection
3. Customer approval are received in case of major
changes Ex. Change of Welch plug from metallic 5. Improved Delivery performance
to rubberised. 6.In process inventory cost reduced.
4. Continuous Process Monitoring implemented 7. Premium freight cost reduced.

Sigma Levels/Improvement Communication & Translation

1.Project is documented.

2.Project results and lesions learned are

shared with stack holders & similar
process owners.

3.Operators are trained in line with the

new process & control plan changes.

4.One point lesions / Quality Alerts are

displayed on the operation stations as
Sigma Level (ST) 1.45 3.38 a supporting documentation.

Eliminate Waste, Built pro-active process control measures

 Project Signoff
Indian Statistical
Institute, Pune 6s
Increase First Time Right Ratio (FTR) of Axle Assembly
CONTROL HAND-OFF SHEET

Core Process: Axle Manufacturing Owner: PRODUCTION MANAGER

Subprocess: CASTING SQE
Owner:
• Policies & Procedures were documented and communicated on 13-Mar-2013
(date)
• I understand the New Policies and Procedures

• I understand and take responsibility for monitoring the Defect Measurements as delineated
by the Project Team

• I will report the progress on this subprocess on a regular basis to the Quality Promotion Council

• I have reviewed this project’s isolated financial benefits with the Project Champion
Rs. Impact Current Year
• I understand the corrective action procedure and am responsible for ensuring that action
items are completed to hold the gains and capture the financial benefits

PRODUCTION MANAGER 13-Mar-2013 SQE 13-Mar-2013

Core Process Owner Date Subprocess Owner Date