Académique Documents
Professionnel Documents
Culture Documents
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1.1
1.2
Project Title i.e. Problem Definition To eliminate the problem of inversion of alternator belt Present Level of Problem :- Every Month 2~3 vehicle on average Held up in HUT Target Taken : - Elimination of problem.
1.3
b) Project Members : Anshul Gupta Archit Garg Salil Jain c) Facilitator : 1.4 Duration of the Project a) Date of Commencement: 05.06.2012 Mr. Vinay Kumar
Brief Description of the Problem The belt coupling the alternator with the fan belt pulley used to get inverted when the tractors were tested after the assembly line. This led to monetary loss to the firm.
1.6
History of Problem
Average
No. of Faults
On an average 2-3 tractor reported for this defect every month. 1.9
2
2.1
2.1
The engines are stored in the store for some days as inventory.
Engine Sub-Assembly
Engine Assembly
Coupling Area
Paint Shop
Dismounting
After roller testing some of the tractors show inversion of alternator belts.
2.2
Observation of Symptoms: The inverted belts hinders power transmission to the alternator.
2.3
Observation of Variation
Model Wise: 735 FE: 843XM: 2624 342 Defected: 0 (0.00%) Defected: 2 (0.58%)
Sales
735FE 843XM
Thus this is dependent on the model type. The problem is found to be prominent with the model 843XM
Shift Wise: Shift A: 1436 Shift B: 1430 Defected: 1(.06%) Defected: 1(.06%)
Shift Wise
A B
3
3.1
3.2
Machine
Belt was put inverted
Man
Alternator misaligned during fitment
Low quality Belt Belt was slack Damage in Paint shop Design flaw
Material
Method
3.3
Verification Of Causes
Sr.No
Probable Cause
Method of Testing
Observations
Inference
The problem does not occur in a batch as should have been the case.
Invalid
Again most of the tractors would have failed had this been the cause.
Invalid
Invalid
Design flaw
Invalid
The assembly comprises of various manual stations. Thus such a case wont sustain.
Invalid
The tightening is done entirely on manual basis without any equipment for standardization. Such a problem would have caused huge no. of failures.
Valid
Invalid
Invalid
3.4
Root Causes: Final Root Causes which came out to be valid is Slack alternator belt.
4
4.1
List of Root Causes, Remedies Developed & Date of Implementation of each remedy The operator should be provided some standardizing equipment like tension gauge, torque
wrench etc.
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5.1
5.2
Intangible Benefits Completely eliminated problem Delivery on schedule and low H.U.T. .
5.3
6
6.1 6.2
STANDARDIZATION
List of Documents changed Alternator belt tightening SOP. Training given to concerned people: 7
CONCLUSION Lessons Learnt Structured way of problem solving technique is helpful in foolproof solutions Gemba analysis is helpful concept to eliminate the problem from root.
Design Suggestion for torque wrench Such shape can be formed out of a metal plate and welded onto a torque wrench at suitable position and there after suitable value for tightening of the alternator belt shall be obtained by experiment. the position where the hook end of the torque wrench may placed is shown by the red mark.
This position is same as that currently been used to tighten the belt using the screw driver so there wont be any problem of leverage.