1

IMPROVE ORIFICE 1.4 INSERTION PROCESS

 HICOM-HONDA MANUFACTURING MALAYSIA SDN. BHD.
KAW. PERUSAHAAN BAKAR ARANG
PETI SURAT 32, 08007 SUNGAI PETANI
KEDAH DARUL AMAN, MALAYSIA.
E-Mail : sales@hicom-honda.com
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IMPROVE ORIFICE 1.4 INSERTION PROCESS
 7th TECHNOLOGY EXCHANGE CONVENTION
DISPLAY
Company Name: HICOM-HONDA
Leader Name: Abd Halim Ahmad 　
Division Name : Manufacturing THEME ： TO IMPROVE ORIFICE 1.4 　　　
Department name: Engineering INSERTION PROCESS Contact no.: 0194802651
Theme categories Gemba Kaizen Technology Company Head :Abd. Halim Ismail
　　　　　
◆Background and Target ・ Goal Manual orifice ◆Before implementation / after implementation
(Perspective ： Q ． C ． D ． M ． E ． Etc. ）insertion to
R Crankcase

CpK = 0.576
◆Point of Technology Air pressure sensor to detect ◆ Investment PROJECT COST =
Replace manual process to
Through oil hole at orifice RM 2,345.00
Pneumatic press ◆Development schedule

◆Replication: To use in all model and breather

joint machine

◆Know How Pneumatic calculation & automation

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IMPROVE ORIFICE 1.4 INSERTION PROCESS
C D M S E
CURRENT PROBLEM
ORIFICE 1.4 INSERTION PROCESS NO
GOOD – DEPTH NOT CONSISTENT
ENGINE LUBRICATION SYSTEM FULLY DEPENDANT ON COMPONENT
INCLUDING THE ORIFICE 1.4.
1.4
WRONG POSITION OF ANY RELATED COMPONENT WILL LEAD TO
TOTAL ENGINE XFAILURE.

ABNORMAL
X = 0.5 ±0.2 X = <0.3mm, >0.7 mm
= 0.3 ~ 0.7 mm

HEIGHT NOT CONSISTENT

PROCESS DRAWING 4
IMPROVE ORIFICE 1.4 INSERTION PROCESS
C D M S E
PROBLEM DEFINITION
PART NAME : ORIFICE,1.4
PART NUMBER : 11133-KWB-6000-H1
MATERIAL : A2011BD
PROCESS : DRILLING,
CHAMFERING & CUTTING
LOCATION : CRANK CASE
COMP,RIGHT

ORIFICE,1.4
LOCATION

LOCATION OF
ORIFICE , 1.4

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IMPROVE ORIFICE 1.4 INSERTION PROCESS
C D M S E
PROBLEM DEFINITION
FUNCTION : - PARTS OF ENGINE LUBRICATION SYSTEM.
- CONTROLLING FLOW OF ENGINE OIL
BETWEEN UPPER MOVING
COMPONENT AND INSIDE ENGINE MOVING
LUBRICATION SYSTEM DIAGRAM
COMPONENT

ORIFICE,1.4
LOCATION

6
IMPROVE ORIFICE 1.4 INSERTION PROCESS
C D M S E
PROBLEM DEFINITION
FUNCTION : - PARTS OF ENGINE LUBRICATION SYSTEM.
- CONTROLLING FLOW OF ENGINE OIL
BETWEEN UPPER MOVING
TO UPPER
COMPONENT AND INSIDE ENGINE MOVING
DEPTH DEPTH BELOW
COMPONENT
MOVING OVER SPEC SPEC
COMPONE OIL LEAK
NT STANDARD AT
HIGH
OIL CYLINDER
PRESSURE
PRESSURE MATING
TO INSIDE
SURFACE
ENGINE
MOVING
COMPONEN
T

LOW
PRESSURE

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IMPROVE ORIFICE 1.4 INSERTION PROCESS
 C D M S E
PROBLEM DEFINITION
FUNCTION : - PARTS OF ENGINE LUBRICATION SYSTEM.
- CONTROLLING FLOW OF ENGINE OIL
BETWEEN UPPER MOVING
COMPONENT
LUBRICATION AND INSIDE ENGINE MOVING
SYSTEM DIAGRAM
COMPONENT

SIDE MOVING COMPONENT

UPPER MOVING COMPONE

ORIFICE,1.4

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IMPROVE ORIFICE 1.4 INSERTION PROCESS
 PROBLEM DEFINITION
IMPACT OF THE PROBLEM TO THE EMITTING TAPPET NOISE
INCORRECT
ENGINE
ORIFICE DEPTH TOTAL ENGINE
FAILURE
CAM BEARING FAILURE

LOW OIL
PRESSURE LOWER ENGINE
EFFICIENCY CAM PROFILE EXCESSIVE WORN OUT
ROCKER ARM EXCESSIVE WORN OUT

NOT ENOUGH
LUBRICATION EMITTING PISTON SCORING
EXTREME HEAT

CRANKPIN AND CONROD

EXCESSIVE WORN OUT
EXCESSIVE
FRACTION EXPEDITE PARTS
BETWEEN WEAR SHAFT BEARING FAILURE
MOVING PARTS
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IMPROVE ORIFICE 1.4 INSERTION PROCESS
 C D M S E
PROBLEM IDENTIFICATION
RIFICE INSERTION PROCESS LOCATION

ENGINE ASSEMBLY LINE SUBSTATION S2

10
IMPROVE ORIFICE 1.4 INSERTION PROCESS
 C D M S E
PROBLEM IDENTIFICATION
ORIFICE INSERTING PROCESS FLOW

ARRANGE PARTS /LOADING INSERT ORIFICE TO OIL HOLE PRESS ORIFICE 1.4 USING HAMME
2 sec 1.3 sec 4 sec

REMOVE PARTS / UNLOADING PROCESS FINISH CHECK OIL HOLE THROUGH

CONFIRMATION
2 sec MARKING
1 sec 2 sec
11
IMPROVE ORIFICE 1.4 INSERTION PROCESS
 C D M S E

PROBLEM IDENTIFICATION
PROBLEM : PROCESS CAPABILITY LOW DUE TO ORIFICE DEPTH NOT
CONSISTENT 1
O
R
I
FHIGH POSSIBLITY OUT OF TOLERANCE!
I
C
E

D
E 0 0.2 0.4 0.6 0.8 1
P
T
AVERAGE 0.52 ＣＰ 0.644
H ＣＰＫ 0.576 (CP )
S T A T US ×

ORIFICE,1.4
PRESS
DEPTH
0.8

0.7 ORIFICE INSERT PROCESS , CpK =

0.576
ORIFICE DEPTH

0.6

0.5

0.4

0.3

0.2

X 0.1

0
ORIFICE 1.4

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

SAMPLE
CRANKCASE

12
IMPROVE ORIFICE 1.4 INSERTION PROCESS
 C D M S E
PROBLEM IDENTIFICATION
PROBLEM : PROCESS CAPABILITY LOW DUE TO ORIFICE DEPTH NOT
CONSISTENT
Every Cpk value corresponds to a percent defective rate, which may be
expressed in parts per million, or ppm.
ORIFICE INSERT PROCESS , CpK = 0.576 = ~ 80,000 ppm
CpK vs. ppm
Cpk Table
Sigma ppm = REJECTION RATE = 8%
0.43 - 193,600
0.47 - 161,510 VOLUME = 7000 / MONTH
0.50 1.50 133,610
MONTHLY:
0.53 - POTENTIAL
109,600 REJECTION = 7000 x 8% = 560 pcs
0.57 - 89,130
0.60 - YEARLY
71,960 :
0.63 -
560 x 12 month = 6720 pcs
57,430
0.67 - 45,500
0.70 - 35,730
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IMPROVE ORIFICE 1.4 INSERTION PROCESS
 C D M S E
TARGET OF IMPROVEMENT
BASE ON THE ORIFICE DEPTH AND CpK DATA

1.8
1.6
PROCESS CpK 1.67
TARGET
1.4

ET
1.2

RG
1
0.8 0.58

TA
0.6
0.4
0.2
0
CURRENT TARGET

WE ARE TARGETING TO IMPROVE ORIFICE 1.4

INSERTION PROCESS
PROCESS CAPABILITY : Cpk 0.576 -> CpK 1.67
AS REQUIRED BY ISO/TS 16949 STANDARD (DESIGN STAGE)

14
IMPROVE ORIFICE 1.4 INSERTION PROCESS
 PROJECT PLANNING
TO IMPLEMENT METHOD TO ENSURE CONSISTENT KNOCKING
FORCE
COUNTERMEASURE SCHEDULE
Month

Status
Item Duration PIC Nov
9 10 11 12 13 16 17 18 19 20 23 24 25
P
Produce Design Concept
A
Design Concept Selection
1 P H
Plan A
Start Design 1 P
A H
P
Design Approval
1.5 A
P
F
Fabrication
A
Do
Installation
0.5 P H
A
P
Check
Trial Run 6 A A
Result & Effectiveness P
Confirmation 1 A
P
N
Action Improvement
A
1 K
1 K
2.5 F

15
IMPROVE ORIFICE 1.4 INSERTION PROCESS
 C D M S E
POINT OF TECHNOLOGY
TO IMPLEMENT METHOD TO PRODUCE CONSISTENT KNOCKING
FORCE
DESIGN CONCEPT : BASE ON PRESSURE EQUATION

F=PxA
F, Knocking force require to insert orifice
P, Pressure to create the knocking force
A, area to receive the force.
(A is consistence because same orifice diameter)

Same knocking FORCE can only be produced if same PRESSURE given.

Human difficult to generate same PRESSURE, every time therefore we suggest to use
Pneumatic System as replacement

16
IMPROVE ORIFICE 1.4 INSERTION PROCESS
 C D M S E
POINT OF TECHNOLOGY
TO IMPLEMENT METHOD TO PRODUCE CONSISTENT KNOCKING
FORCE
CONSISTENT AIR PRESSURE
CONSISTENT AIR PRESSURE

INCONSISTENT MUSCLE
FORCE

PRESSURE
AIR

FORCE
REGULATO
AIR

FORCE
R
HAMMER REGULATO
R

DEVICE
HAMMER

ORIFICE DEVICE

ORIFICE

CONCEPTUAL STAGE 17
IMPROVE ORIFICE 1.4 INSERTION PROCESS
 C D M S E
POINT OF TECHNOLOGY :1
TO IMPLEMENT METHOD TO PRODUCE CONSISTENT KNOCKING
FORCE
CONSISTENT AIR PRESSURE

AIR
FORCE

REGULATO
R

FINAL CONCEPT DESIGN STAGE 18

IMPROVE ORIFICE 1.4 INSERTION PROCESS
C D M S E
POINT OF TECHNOLOGY :1
TO IMPLEMENT METHOD TO PRODUCE CONSISTENT KNOCKING
FORCE

FABRICATION STAGE INSTALLATION STAGE

19
IMPROVE ORIFICE 1.4 INSERTION PROCESS
 IMPROVEMENT 1
TO IMPLEMENT METHOD TO PRODUCE CONSISTENT KNOCKING
FORCE
CONSISTENT AIR PRESSURE

AIR
FORCE

GRAPH AIR PRESSURE VS ORIFICE DEPTH

REGULATO
R 7.5
7
LCL ST UC
6.5 D L
6
5.5

AIR PRESSURE (PSI)

5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
-0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
ORIFICE DEPTH

DATA SHOWN THE BEST PRESSURE SETTING IS

4.5 psi ~ 5.5 psi

INSTALLATION STAGE 20
IMPROVE ORIFICE 1.4 INSERTION PROCESS
C D M S E
POINT OF TECHNOLOGY :1
TO IMPLEMENT METHOD TO PRODUCE CONSISTENT ORIFICE
DEPTH
DEPTH LIMITER
– ADJUSTABLE LIMITER
AT THREE POSITION
FOR CONTROLLING
PRESS TRAVEL

21
IMPROVE ORIFICE 1.4 INSERTION PROCESS
C D M S E
POINT OF TECHNOLOGY :1
TO IMPLEMENT METHOD TO PRODUCE CONSISTENT KNOCKING
FORCE
PNEUMATIC CYLINDER DEPTH LIMITER
– PROVIDE CONSISTENT – AT THREE POSITION FOR
TONNAGE CONTROLLING PRESS TRAVEL

LIGHT
AIR CLAMP – VISUAL AID TO MACHINE
– TO FIX PARTS POSITION OPERATOR
GRAPH AIR PRESSURE VS ORIFICE DEPTH

7.5
7

SURROUND CAGE
6.5
6
5.5

AIR PRESSURE (PSI)

5

– SAFETY DURING MACHINE

4.5
4
3.5
3
2.5

UNDER OPERATING 2
1.5
1
0.5
0
-0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
ORIFICE DEPTH

PARTS JIG
– FIX PART POSITION BEST PRESSURE SETTING IS
4.5 psi ~ 5.5 psi

ADJUSTABLE BASE
– TO ENSURE BEST MACHINE
COMPLETE AIR REGULATOR
– PROVIDE CONSISTENT AIR
LEVELLING PRESSURE
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IMPROVE ORIFICE 1.4 INSERTION PROCESS
 C D M S E
RESULT VERIFICATION
IMPROVE ORIFICE 1.4 INSERTION PROCESS
PREVIOUS ORIFICE INSERTING PROCESS CYCLE TIME BEFORE

ARRANGE PARTS / LOADING INSERT ORIFICE PRESS ORIFICE ( HAMMER

REMOVE
) PARTS / UNLOADING MARKING CHECK OIL HOLE THROUGH
2 sec 1.3 sec 4 sec 2 sec 1 sec 2 sec
NEW ORIFICE INSERTING PROCESS CYCLE TIMEAFTER
INSERT ORIFICE LOADING PARTS CLAMP AND
START PRESS
1.3 sec 2 sec 1 sec

CHECK OIL UNLOADING PRESS ORIFICE

HOLE PARTS
THROUGH
2 sec 2 sec 2 sec

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IMPROVE ORIFICE 1.4 INSERTION PROCESS
 C D M S E
RESULT VERIFICATION
TO IMPLEMENT METHOD TO PRODUCE CONSISTENT KNOCKING
FORCE
BEFORE
0.8

0.7

ORIFICE DEPTH
ORIFICE,1. 0.6

0.5
4 PRESS 0.4 CpK = 0.576
1
DEPTH 0.3 O
R
0.2 I
F
0.1 I
C
0 E
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
D
0 0.2 0.4 0.6 0.8 1
DATA E
P
T
AVERAGE 0.52 ＣＰ 0.644
H ＣＰＫ 0.576 STATUS(CP)
×

THE DATA 0.8

0.7
AFTER
SHOWN
ORIFICE DEPTH

0.6

0.5
CpK = 2.519
THE
0.4

0.3
AVERAGE = 0.51mm
ORIFICE 1.4
0.2

0.1

PRESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

DATA

DEPTH IS
VERIFICATION
CONSISTEN STAGE
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T IMPROVE ORIFICE 1.4 INSERTION PROCESS
 C D M S E
RESULT VERIFICATION
IMPROVE ORIFICE 1.4 INSERTION PROCESS
CYCLE TIME (SEC)
BEFORE
5
AVERAGE CYCLE
4 TIME PER PARTTIME
= (SEC)
12.3 sec
4

REDUCE 2 SEC
2 2 2
2
1.3
1
1

0
FROM 12.3 SEC 10.3
LOADING
PART
INSERT
ORIFICE
PRESS
ORIFICE
CHECK OIL
HOLE
MARKING UNLOADING SEC

CYCLE TIME (SEC)

5
TIME (SEC)
AFTER
4 AVERAGE CYCLE TIME PER PART = 10.3 sec
3
2 2 2 2
2
1.3
1
1

0
INSERT LOADING CLAM AND PRESS UNLOADING CHECK HOLE
ORIFICE PART START ORIFICE

25
IMPROVE ORIFICE 1.4 INSERTION PROCESS
C D M S E
RESULT VERIFICATION
IT IS BASE ON THE ORIFICE DEPTH AND CpK DATA

3
2.519
< 0.00198 ppm
2.5

2 1.67

1.5

1 0.58

ET
0.5
R G
0
CURRENT
TA TARGET ACTUAL

26
IMPROVE ORIFICE 1.4 INSERTION PROCESS
C D M S E
POINT OF TECHNOLOGY : 2
TO ELIMINATE MANUAL OIL HOLE CHECKING

Oil hole checker

ORIFICE 1.4 INSERTION PROCESS C.T
12

11 10.3

10

TA 8.3
9
R GE
8 T
7
100% CHECK OIL HOLE THROUGH
TIME (SEC)
5 6
CURRENT TARGET
4

3
2 2 2 2
2
1.3
1
1

0
INSERT LOADING CLAM AND PRESS UNLOADING CHECK HOLE
ORIFICE PART START ORIFICE

27
IMPROVE ORIFICE 1.4 INSERTION PROCESS
C D M S E
POINT OF TECHNOLOGY : 2
TO ELIMINATE MANUAL OIL HOLE CHECKING
AIR
PRESSURE
AIR PRESSURE SWITCH – AIR PRESSURE SWITCH –
DETECT ANY AIR PRESSURE CHANGES DETECT ANY AIR PRESSURE CHANGES

PRESSURE
GREEN INCREASE GREEN
LIGHT LIGHT

RED RED
LIGHT LIGHT

HOLE NOT THROUGH

HOLE DETECTION DURING ORIFICE PRESS

CONCEPTUAL STAGE
28
IMPROVE ORIFICE 1.4 INSERTION PROCESS
C D M S E
POINT OF TECHNOLOGY : 2
TO ELIMINATE MANUAL OIL HOLE CHECKING

DESIGN STAGE

FABRICATION AND INSTALLATION STA

29
IMPROVE ORIFICE 1.4 INSERTION PROCESS
C D M S E
POINT OF TECHNOLOGY : 2
TO ELIMINATE MANUAL OIL HOLE CHECKING

GREEN LIGHT RED LIGHT

DETECTION SYSTEM
UNDER OPERATING BUZZER SOUND
& INDICATE ORIFICE
1.4 OIL HOLE INDICATE ORIFICE
THROUGH 1.4 OIL HOLE NOT
THROUGH
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IMPROVE ORIFICE 1.4 INSERTION PROCESS
 C D M S E
COST SAVING
VOLUME = 7000 / MONTH

MONTHLY:
POTENTIAL REJECTION = 7000 x 8% = 560 pc

YEARLY :
560 x 12 month = 6720 pcs

CRANKCASE COST PER UNIT : RM 28.897

COST OF SPOILAGE : 6720 x 28.897 = RM 194,187.8

PROJECT COST = RM 2,345.00
PORTUNITY COST SAVING = RM 191,842.8
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IMPROVE ORIFICE 1.4 INSERTION PROCESS
C D M S E
STANDARDIZATION
MACHINE CHECKSHEET ORIFICE 1.4 INSERT
MACHINE SOP

TRAINING ATTENDANCE PROCESS BRIEFING

32
IMPROVE ORIFICE 1.4 INSERTION PROCESS
 HORIZONTAL REPLICATION
TO OTHER MODELS AND BREATHER JOINT
ASSEMBLY
BREATHER
PROCESS
JOINT

CHANGE
TO

AUTOMATION USING CONSISTENT AIR PRESSURE

MANUAL INSERTING PROCESS
33
IMPROVE ORIFICE 1.4 INSERTION PROCESS
THANK YOU

34
IMPROVE ORIFICE 1.4 INSERTION PROCESS