Review Presentation: Sahil Karodia Engineer P&F

REVIEW PRESENTATION
Sahil Karodia
Engineer
P&F
© Subros Limited. All rights reserved

TRAININGS UNDERGONE
SR.NO. TRAININGS PLANNED ACTUAL
1 DNJP INTRO. OK COMPLETED
2 SAP AWARENESS OK COMPLETED
3 SERVICE AND VEHICLE PREPARATION OK COMPLETED

4 GD&T OK COMPLETED
5 IMS OK COMPLETED
6 PROBLEM SOLVING TECHNIQUE OK COMPLETED
7 METROLOGY OK COMPLETED
8 TIE OK COMPLETED
9 PLM OK COMPLETED
10 7QC OK COMPLETED
11 LOTUS NOTES OK COMPLETED

LEARNINGS DURING SHOP FLOOR TRAINING
1. Basic Understanding Of Automotive Air Conditioning and Product

Awareness
2. Hands on experience on work stations.
3. Learning the basic and critical parameters, pokayoke for each

respective station.
4. Basic understanding of W LT machine,Crimping machine etc..
5. Basic awareness about functioning of each department & their

collaborative work.
6. Exposure to Red Bin Area

KAIZEN Activities
ISSUE OBSERVED: PLACEMENT OF LPG GAS CYLINDER INSIDE THE OIL STORAGE AREA .
BEFORE AFTER
COMMENT: AS LPG STOARGE NEAR OIL COMMENT:LPG STOARGE AREA SEPARATED

AREA MAY CAUSE THE POSSIBILITY OF FIRE FROM OIL STOARGE AREA ELIMINATING THE
HAZARD. POSSIBILITY OF FIRE HAZARD, BY PROVIDING
SEPARATE SHADE & COST IS SAVED BY USING
SCRAP MATERIAL.
1) 5S IMPROVED (2)POSSIBILITY OF FIRE

BENEFIT: HAZARD ELIMINATED.
KAIZEN
TITLE: Proper Instructions made available to reduce operator fatigue
BEFORE AFTER
No proper Instruction manual for type of Proper instructions made available for type of
clamp, length of insulator fitment, with clamp to be used,insulator to be used for each model
their model & part number.. along with other details.
1) 5S IMPROVED
BENEFIT: 2) OPERATOR FATIGUE REDUCED
3) PROPER SELECTION ISSUE REMOVED
List of Projects selected
S. PROJECT NAME STARTING COMPLETION STATUS

No. DATE DATE
1 Customer Complaint of Abnormal 06/01/14 10/04/14 Complete

Noise in Blower motor.
2 To reduce preheating downtime of 19/12/14 15/03/14 Complete

Injection Moulding machine by Hot
Air dryer system.
3 Productivity Improvement in Model 02/01/14 09/02/14 Complete

U HVAC line.
4 Error Proofing for wrong TXV 18/05/14 - In Progress

assembly In HVAC.

Project Title : Customer complaint of Abnormal Noise in Blower Motor
Team Formation :
Mr. Sahil Karodia (P&F)
Mr. Hruday Ambati(Customer Service)
Mr. Vinay ( PQA)
Mr. Amol (Customer Service)
Mr. M.Mandal (Vendor)
Problem Description :
Abnormal Noise reported in Blower motor of Indica/Indigo HVAC at Tata Motors PCBU
block during drive test.This noise was resulting into customer dissatisfaction.
Reason for selection : Customer Complaint
Start Date : 06.01.14

Target Date : 05.03.14

Data Collection :
In Indigo HVAC abnormal noise was reported in Blower motor from Tata
motors PCBU block during drive test. In the month of January 14, total 13
number of cases were reported from TML.
14 13
12
N u m b e r o f ca s e s re p o rte d
10
0
Jan'14

Analysis :
Customer Complaint : Blower Motor Noise - Indigo
Date : 10.02.14
Qty : 05 Nos
Occurrence period : Jan 14
Vendor : Denso India Ltd.
Reported by : TML PCBU – during Drive Test
Initial Observations : Subjective noise
Detection method at Subros : Blower Test Bench at EOL
Quantification of Noise : Measurement by dB meter at vehicle level planned

as the noise is Subjective.

Data Collection of Noise
A C
Vehicle & Chassis Number details
Taken for data collection -
Note :
'Ok' indicates Cleared vehicles
'NG' indicates Hold vehicles due to

subjective Noise
Measurement conditions :
1. Engine On
2. AC On
3. Face Mode
4. Recirculation mode On
5. Measured at co-driver's ear
6. Measured on test track
7. Measured by dB meter

Data Collection of Noise

Quantification of data
Blower Motor Noise measurement in Db at vehicle level - Quantification
Inference from data –

All 5 reported blower motors ( S No – 1, 2, 12, 13, 31) have noise level less than
Ok blower motors when quantified in dB.
QC Tool : Cause & Effect Diagram P D
A C
Machine Man
Unskilled operator
Machine used
for process not Less skill level
calibrated Work Instruction
Improper
Abnormal Noise
Armature NG Shaft Length More/Less
Housing A Damage Inspection Not Proper More Torque than Specification
Housing A Brearing torque

Carbon Brush Damaged Housing B NG
Less Torque than Specification
Shaft Roughness NG Mishandling during

Shaft Roundness NG Assy. process
Material Method

Significance Test – To Check & identify potential significant causes
for an effect
Test for Significance :

S. No Probable Cause Significance test Result
1 No Load Current No load current was as per

NG specification & found OK.
Specification: 2.5A max. Insignificant
Actual: 2.4 A.
2 Axial Play Axial play in blower motor samples

were found as per specification. Insignificant
Specification: 0.02-0.5mm
Actual : 0.22mm

for an effect
3 Shaft Roughness Roughness was found more than

limits.. Significant
Specification: 0.8 Rz Max.
Actual : 0.88 Rz
4 No Load Speed No load Speed of blower motor was

checked & was found within Insignificant
specification.
Specification : 4200 rpm Min.
Actual:4485 rpm

for an effect
5 Armature Dent mark was found on Armature.

Damaged/NG Armature was replaced in NG Significant
Blower motor & no abnormal noise
in motor
6 Housing Bearing Housing A & B tilting torque was

torque checked & found Ok. Insignificant
Specification: 2-6 Kgf.cm2.
Actual: 3.8 Kgf.cm2

for an effect
7 Improper Handling/ Material handling was satisfacory &

Transit Damage found OK.
Insignificant
8 Shaft Roundness Shaft Roundness was checked & is

within Specification & found Ok. Insignificant
Specification: 0.8 Rz Max..
Actual: 0.36 Rz

QC Tool : Cause & Effect Diagram P D
A C
Machine Man
Unskilled operator
Machine used
for process not Less skill level
calibrated Work Instruction
Improper
Abnormal Noise
Armature NG Shaft Length More/Less
Housing A Damage Inspection Not Proper More Torque than Specification
Housing A Brearing torque

Carbon Brush Damaged Housing B NG
Less Torque than Specification
Shaft Roughness NG Mishandling during

Shaft Roundness NG Assy. process
Material Method

WHY-WHY Analysis
Motor Noise level is in higher side
WHY ?
Dent Scratch on Armature
WHY ?
Possibility of dent on armature shaft

during picks/place time at ering process
WHY ?
Armature shaft was hitting with metal

block at ering press fit process

Actions taken against Observations
Counter Measures :
 Metalic block was replaced by Nylon block to eliminate shaft
dent possibility at ering press fitting process.
 100% Motor check for all orientation at final inspection area &
check point added in operator manual sheet at vendor end.
Checkpoints/ Standardization :
 Maintenance sheet for jigs & Fixtures.

 Modification in Inspection manual.
 Modification in operator's Training manual.

Analysis report by Vendor

Monitoring Effectiveness
Number of complaints of
abnormal noise of blower motor
reduced by 61.5% .
14 13
12
10
Number of complaints
8
6 6
6 5
0
Jan'14 April'14 May'14 June'14
Month

Learning from Project

Usage of QC Tools.

Usage of DB Meter.

Usage of problem solving techniques.

Noise level detection at customer end.

Vehicle level fitment of AC kit at customer end.

Project-II
MPS PROJECT
PRODUCTIVITY IMPROVEMENT IN
MODEL U HVAC LINE_ REAR
IMPLEMENTING MARUTI PRODUCTION SYSTEM PRACTICES
TARGET COMPLETION DATE: FEB'2014

REASONS FOR SELECTING THE PROJECT P D
A C
1. PRODUCTIVITY INCREASE FROM CURRENT LEVEL OF
180 NOS./ SHIFT TO 265 NOS./ SHIFT.
2. IDLE TIME FOR OPERATORS.
3. MUDA OF MOVEMENT.
4. MATERIAL HANDLING CONCERNS.
5. LAYOUT ISSUES OBSERVED FROM PRODUCTIVITY &

MANPOWER ALLOCATION POINT OF VIEW.

MPS PROCESS FOLLOWED P D
A C
Re-analysis
Identification of lines Implementation of Kaizens
Machine/equipment to be as
Planning of Kaizens
per the Existing standard
Target setting Standard Operation

Combination Chart
Video photography Work Balance Bar Chart
Elemental Analysis Identification of Bottleneck

TEAM FORMATION P D
A C
A team was formed including members all cross functional team members from
Production, TIE, P&F, Maintenance..
S.NO. Name Department

1 Mr. Sahil Karodia P&F
2 Mr. Prashant Pednekar Production
3 Mr. Shashank Kulkarni TIE
4 Mr. Bapun Kar Production
5 Mr. Amol Maintenance

PROJECT TARGETS P D
A C
 To improve HVAC – Model U_ Rear production from
180/shift to 265/shift by reducing NVA activities, along with line
balancing with layout change activity.
 Effective utilisation of manpower on Evaporator case matching,
DLT & Blower test bench along with harness along with Final
Inspection stations.
 To improve Line balance efficiency on above stations.
 To reduce muda of motion at bottleneck operations.
 To improve workplace layout of overall line stations.
 To improve Visualization on assembly line.
 To improve Ergonomic on all stations, to reduce operator
fatigue.

TARGET SETTING P D
A C
Note - New target with 10 manpower will be 330.

MPS ACTIVITY PLAN
TARGET COMPLETION DATE: FEB 2014

AVAILABLE TIME P D
A C
Shift Time : 7:00 ~ 3:30 PM

Total Time: 8 Hours & 30 minutes = 510 Minutes
Break Time:
Lunch : 30 Minutes
Tea ( Two Times ): 10+10= 20 Minutes
Start -Up check sheet fillings= 10 Minutes
Total Break Time : 60 Minutes
Available Time:
510 - 60 = 450 Minutes = 27000 Sec
PROCESS FLOW: BEFORE P D
A C
S/A DETAILS INPUT
Evaporator S/A & Evaoporator packing &

Torquing Bracket assly
Case “O” ring Case Matching- Evaporator

fittment
Blower motor S/A Motor & harness assly
Relay fittment OUTPUT
DLT checking EOL
Blower test bench

Harness checking

PROCESS LAYOUT: BEFORE P D
Motor
A C
S/A
Evapo
M G Torquing “O” ring to
case
O A
L N Evaporator
Packing &
Case Motor & Relay Assly DLT checking Blower test
bench
Harness
testing
EOL tseting
matchings harness assly
D G Bracket assly
I W Input
N A
G Y Output
S S Proper work distribution not

Proper work distribution not
observed. observed.
TOTAL MANPOWER =10 NOS/ SHIFT (Previous)

ELEMENTAL BREAK UP (CRITICAL PROCESS)
As per Elemental study conducted for the assembly line, major scope of improvement identified at the
following stations. (1)Relay Assembly & DLT (2) Blower test bench (3)Harness checkings

ELEMENTAL BREAK UP (CRITICAL PROCESS)
Percenta
Category Symbol Secs ge(%)
Sealable 49.98 49.1
Non s elabale 36.02 35.38
Was te 15.79 15.51

Total (Secs) 102 100

WORK BALANCE CHART- BEFORE P D
A C
-> Output/shift = 180 (Actual achieved) nos/shift
- > with manpower 10 Nos.
120.0
100.0 16.0
25.3 18.2 24.1
80.0 10.0
36.0 14.3 21.5 9.6 14.3
60.0 32.8 31.1 35.0 13.7
48.5 6.1
25.6 10.6
40.0
51.0 60.0 59.6 28.5 50.4
20.0 45.1 34.3 8.7 43.1 40.4
16.3 17.0
Time 0.0
Evaporator S/A & Torquing
Evaporator packing & bracker assembly
Case matchings
Motor & harness assembly
Relay assembly
DLT Checkings
Blower motor sub assembly
Blower test bench
Harness checkings
EOL Final Inspections

(Sec) Waste
Non sealable
Sealable
Station description
Total waste Time= 207 Sec
Total Non Saleble Time = 229 Sec
KAIZEN IMPLEMENTATION P D
A C
Model U line
Sr. No. parameters Existing Target Achieved
1 Production per shift 180 265 210
2 Manpower 10 8 8
3 Shift hours 7.67 7.67 7.67
4 Productivity/man/shift 18.0 33 26
5 Productivity Improvement 84.03% 45.83%
LEGEND : A CLASS – INVESTMENT UPTO RS.500/- IMMEDIATELY IMPLEMENTATION
B CLASS - INVESTMENT UPTO RS.10000/- IMPLEMENTATION WITHIN ONE MONTH
C CLASS - INVESTMENT MORE THAN RS.10000/-IMPLEMENTION WITHIN 3 MONTHS

KAIZEN SHEET

KAIZN- 1
TITLE: RACK PROVISION MADE NEAR TO STATION FROM MATERIAL STORAGE POINT
OF VIEW
BEFORE AFER

KAIZEN- 2
TITLE: LINE BALANCING ACHIEVED BY CHANGE IN LAYOUTS
BEFORE AFTER
COMMENT:PIPE INSULATION & LEVER COMMENT: PIPE INSULATION STATION ALONG WITH
SUBASSEMBLY STATIONS AVAILABLE AT LEVER SUBASSEMBLY STATIONS MADE AVAILABLE
SEPARATE LOCATIONS. AT SAME LOCATIONS SO AS TO ACHIEVE THE LINE
BALANCING BY REDUCING 1 MANPOWER
BENEFIT:1) 5S IMPROVED (2)OPERATOR FATIGUE

REDUCED (3)1 MANPOWER
REDUCTIONS
KAIZEN- 3
TITLE: ERGONOMIC POINT OF VIEW, MOTORS TO COME IN TROLLIES.
BEFORE AFTER
.
COMMENT: AT PRESENT MOTORS COMMENT:AS PER FUTURE PLAN , THE
ARE COMING IN BINS, ERGONOMIC MOTORS HAVE TO COME IN TROLLIES
POINT OF VIEW NOT CORRECT ONLY. OPERATION TIME REDUCED BY 4
SECS
BENEFIT: 1) 5S IMPROVED
2)ERGONOMICS TO BE IMPROVED.
3) SPACE SAVINGS TO BE ACHIEVED. (4)OPERATION TIME REDUCED BY 4 SECS
KAIZEN- 4
TITLE: MATERIAL STORAGE RACK AT THE BACK SIDE, ERGONOMIC
CONSTRAINTS
BEFORE AFTER
.
COMMENT: MATERIAL AT 180 COMMENT: MATERIAL MADE
DEGREE POSITIONS. AVAILABLE AT 90 DEGREE SO AS TO
AVOID ERGONOMIC ISSUE. TIME SAVED
6 SECS PER JOB
BENEFIT: 1) 5S IMPROVED (2) ERGONOMICS
IMPROVEMNTS (3) OPERATOR FATIGUE
REDUCED (4) OPERATION TIME SAVED.
KAIZEN- 5
TITLE: CTQ & CTP STATIONS IDENTIFICATION NOT
BEFORE AVAILABLE AFTER
.
COMMENT:CTQ & CTP STATIONS COMMENT: CTQ & CTP IDENTIFICATION
IDENTIFICATION NOT AVAILABLE ON MADE AVAILABLE ON STATIONS. EASE
LINE. FOR APPOINTING SUITABLE MANPOWER
BENEFIT: 1) STATION IDENTIFICATION MADE
AVAILABLE.
2) EASY TO OPERATE SUITABEL MANPOWER.
KAIZEN- 6
TITLE: NAME PLATE PROVION MADE FOR IDENTIFICATION PURPOSE.
BEFORE AFTER
.
COMMENT: NO NAME PLATE COMMENT: NAME PLATE PROVISION
PROVISIONS FOR THE MADE FOR THE SAME ON LINE.
IDENTIFICATION POINT OF VIEW
2) MATERIAL HANDLING IMPROVED
3) QUALITY IMPROVED
KAIZEN- 7
TITLE: SPACE UTILISATION ACHIEVED BY PROVIDING SMALLER SIZE TROLLEY
BEFORE AFTER
.
COMMENT: LARGER SPACE COMMENT: SMALLER SIZE TROLLEY
ACQUIRED BY THE MASTER SAMPLE MADE AVAILABLE FOR MASTER
STORAGE TROLLEY. SAMPLE STORAGE POINT OF VIEW.
2) MATERIAL HANDLING IMPROVED
3) SPACE UTILISATION IMPROVED BY 25%
KAIZEN- 8
TITLE: WORK INSTRUCTION DISPLAY PROVISION MADE ON EACH WORK
STATION.
BEFORE AFTER
.
COMMENT: WORK INSTRUCTIONS COMMENT:SUITABLE WORK
DISPLAY SYSTEM WAS NOT PROPER. INSTRUCTION DISPLAY PROVISION
FOLDERS MADE ON WORK STATIONS.
2) PROPER WORK INSTRUCTION DISPLAY PROVIONS
3) QUALITY IMPROVED

KAIZEN- 9
TITLE:COLOUR CODIFICATIONS NOT AVAILABLE FOR REWORK TROLLIES.
BEFORE AFTER
.
COMMENT: REWORK PURPOSE PROPER COMMENT:REWORK POINT OF VIEW
COLOUR CODIFICATIONS NOT PROPER COLOUR CODIFICATIONS
AVAILABLE (YELLOW COLOUR CODE) MADE AVAILABLE TO THE TROLLIES.
2)COLOUR CODE IDENTIFICATIONS MADE AVAILABLE
TO THE TROLLIES.
3) MATERIAL MIXING & RELATED ISSUES RESOLVED.
PROCESS FLOW CHART P D
BEFORE A C
AFTER
S/A DETAILS INPUT
INPUT Evaporator Evaoporator
S/A & packing & AFTER
Evaporator Torquing Bracket assly
Evaoporator
S/A & packing &
Torquing Bracket assly
Case “O”
ring fittment Case Matching-
& BL Mtr Evaporator
Case “O”
ring fittment Case Matching- S/A
& BL Mtr Evaporator
S/A Motor & harness
assly
Motor & harness
assly
Relay fittment
& DLT Checking
OUTPUT
Relay fittment
Blower test
bench
& Harness Checking
DLT checking EOL
EOL
Blower test bench Harness checking
OUTPUT
PROCESS LAYOUT: BEFORE P D
A C
Input Motor Manpower = 10 nos /Shift
G S/A
BEFORE
A Evapo
Torquing “O” ring to
case
N
G Evaporator
Packing &
Case
matchings
Motor & Relay Assly DLT checking Blower test
harness assly bench
Harness
testing
EOL tseting
Bracket assly
W
Output
A
Y Proper work distribution
S not observed.
Manpower = 8 nos /Shift

G Input Motor
A Evapo
S/A
AFTER
N Torquing “O” ring to
case
G Evaporator Relay Assly

Blower test
bench & EOL
Case Motor &
W Packing &
Bracket assly
matchings harness asslyDLT Checking Harness tseting
A Output
Y
WORK BALANCE CHART- AFTER P D
A C
1) Reduction in Non Saleable
activity time achieved by 5%.
2) Reduction in Waste activity
time achieved by 39%.
Time
(sec)
Time
Station Details
Total Waste Time= 126 Sec
Manpower = 8 nos/shift Total Non Saleable Time= 217 Sec
MPS TIME PLAN VS ACTUAL

TARGET VS ACTUAL P D
A C
Model U line
Sr. No. parameters Existing Target Achieved
1 Production per shift 180 265 210
2 Manpower 10 8 8
3 Shift hours 7.67 7.67 7.67
4 Productivity/man/shift 18.0 33 26
5 Productivity Improvement 84.03% 45.83%
Target achieved with 10 manpowers is 260.
Learnings from project
 Understanding & Implementation of Maruti Production System in

assembly line.
 Productivity Calculation.
 Understanding of Process Flow diagrams & symbols.
 Line Balancing of assembly lines.
 Removal of various types of Mudas like
i. Muda of movement.
ii. Muda of Inventory.
iii. Muda of Idle time.

Project III : To Eliminate Preheating downtime for ABS material
in Injection Moulding Machine (JSW 850 T).
Team Formation :
Mr. Shrikant Temak (D.M. P& F)
Mr. Sahil Karodia (Engineer P&F)
Mr. Shashank Kulkarni (D.M. P & F)
Mr. Amol (Engineer Maintenance)
Mr. Sangay Lama (Engineer P&F)
Problem Description :
.
The Preheating time of ABS material is 3~4 hours, in this time the Injection Moulding
machine (JSW 850T ) remains Idle resulting in low productivity of machine. .

Brief Description
 A independent set up of Hot air dryer system will be used for pre heating of
ABS (Acrylonitrile Butadiene sterene) material.
 We will run both the machines Injection Moulding machine 850 T (JSW make)
and Hot air dryer (Toshiba Make) .When ABS material is pre heated in the hot
air dryer, we can parallelly run the Injection Moulding machine 850T for other
material.
 Thereby reducing pre heating downtime of Injection Moulding Machine 850T&

enabling quick changeover.we will eliminate idle time of injection moulding
machine 850T.

 ABS material is used as a raw material for four individual moulding
parts of Safari Merline roof Ac kit.
1. Case Upper 645440-2220-0-H
2. Case Lower 645440-2230-0-H
3. Adaptor Suction 645440-0670-0-H
4. Adapter Discharge 645440-0680-0-H
 Requirement of Merline roof AC kit : 900 Kits/Month (Peak volume).

900 kits X 4 parts = 3600 individual parts/month.

Total Downtime
Downtime of JSW 850T :
The preheating time for ABS material is about 3~4 hours approx.
Downtime per run = 3 hours(preheating time) X 4 moulds (Mould for

each part)
= 12 hours.
Downtime per month = 12 Hours X 3 Run (in a month)

= 36 Hours.

Moulding Machine : 850 Ton JSW MAKE
Material : ABS in Granular Form

Throughput : @ 60 Kg per Hour
Drying Temperature: 80~90 ° Centigrade
Drying Time : 3 ~ 4 Hours

Project Summary In details
 Product - Toshiba Hot Air Dryer MODEL LHD 300 with

Toshiba Vacuum Loader Model SSL06
 Customer - TML
 Model - SAFARI Merlin Roof Ac
 Present condition - Existing hopper & loader in Injection Moulding

Machine 850 T
 Benefits - Reduction in machine downtime & Quick
changeover between different materials.
 Investment - 2.49 lakhs + ( taxes & duties )

Investment Details

Moulding Machine Cost Sheet

ROI for Hot Air Dryer

Hot Air dryer set up
Hot Air Dryer system Vacuum Loader

Hot Air dryer & vacuum Loader installed as per plan & training given to
concerned agencies.
Trial conducted & currently Hot Air dryer is being used for mass production.
Total Downtime of 36 hours per month is eliminated.

Current Projects
 Error Proofing for wrong TXV assembly in HVAC.

 Reduction of warpage in Safari cases by making standard cooling Fixtures.
 Productivity Improvement in safari HVAC line by implementing maruti production
system practices.
 JFT development of U-301 Project.

Learnings in Department
• Process designing and Documents Preparation & update of

1) PFD (Process flow Diagram).
2) PFMEA (Process Failure mode & Effect Analysis)
3) Control Plan
• Hands on experience in APQP Production server (Aquapro Ver. 4.5.0).
• Basic Understanding of Subros JFT development Process.
• Basic awareness of Time study.
• Basic understanding of Implementing Maruti Production System on
assembly line.

Thank You

Review Presentation: Sahil Karodia Engineer P&F

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Review Presentation: Sahil Karodia Engineer P&F

Uploaded by

Copyright:

Available Formats

REVIEW PRESENTATION

© Subros Limited. All rights reserved

1 DNJP INTRO. OK COMPLETED

2 SAP AWARENESS OK COMPLETED

3 SERVICE AND VEHICLE PREPARATION OK COMPLETED

6 PROBLEM SOLVING TECHNIQUE OK COMPLETED

11 LOTUS NOTES OK COMPLETED

1. Basic Understanding Of Automotive Air Conditioning and Product

2. Hands on experience on work stations.

3. Learning the basic and critical parameters, pokayoke for each

4. Basic understanding of W LT machine,Crimping machine etc..

5. Basic awareness about functioning of each department & their

6. Exposure to Red Bin Area

© Subros Limited. All rights reserved

COMMENT: AS LPG STOARGE NEAR OIL COMMENT:LPG STOARGE AREA SEPARATED

1) 5S IMPROVED (2)POSSIBILITY OF FIRE

S. PROJECT NAME STARTING COMPLETION STATUS

1 Customer Complaint of Abnormal 06/01/14 10/04/14 Complete

2 To reduce preheating downtime of 19/12/14 15/03/14 Complete

3 Productivity Improvement in Model 02/01/14 09/02/14 Complete

4 Error Proofing for wrong TXV 18/05/14 - In Progress

© Subros Limited. All rights reserved

Reason for selection : Customer Complaint

Start Date : 06.01.14

© Subros Limited. All rights reserved

© Subros Limited. All rights reserved

Occurrence period : Jan 14

Vendor : Denso India Ltd.

Reported by : TML PCBU – during Drive Test

Initial Observations : Subjective noise

Detection method at Subros : Blower Test Bench at EOL

Quantification of Noise : Measurement by dB meter at vehicle level planned

© Subros Limited. All rights reserved

'NG' indicates Hold vehicles due to

© Subros Limited. All rights reserved

© Subros Limited. All rights reserved

Inference from data –

Housing A Brearing torque

Shaft Roughness NG Mishandling during

© Subros Limited. All rights reserved

Test for Significance :

1 No Load Current No load current was as per

2 Axial Play Axial play in blower motor samples

© Subros Limited. All rights reserved

S. No Probable Cause Significance test Result

3 Shaft Roughness Roughness was found more than

4 No Load Speed No load Speed of blower motor was

© Subros Limited. All rights reserved

S. No Probable Cause Significance test Result

5 Armature Dent mark was found on Armature.

6 Housing Bearing Housing A & B tilting torque was

© Subros Limited. All rights reserved

S. No Probable Cause Significance test Result

7 Improper Handling/ Material handling was satisfacory &

8 Shaft Roundness Shaft Roundness was checked & is

© Subros Limited. All rights reserved

Housing A Brearing torque

Shaft Roughness NG Mishandling during

© Subros Limited. All rights reserved

Motor Noise level is in higher side

Dent Scratch on Armature

Possibility of dent on armature shaft

Armature shaft was hitting with metal