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7 Step QC story
SUMO Front Brake pad worn out
Slide 1
7 Step QC story
Problem Solving Methodology
Step: 1 Define Project: Team Charter & Goal Statement
Team Charter
Goal
Structure
Team Leader
- Mr.Bisen Badal
Co - Leader
Team Members Mr. Jagdish G Naganoor, Mr.K.Pavan, Mr.Karadi S.B, Mr.Gharat .R.V,
Mr.Kulkarni S.G, Mr Mhaske, Mr Deshpande.R, Mr Patil suhas,Mr
Diwakar.R, Mr Satyajit Patil.
Target
Training Needs
Current Status
Target
Model
SUMO GOLD
0.66+1.99
Review Mechanism
Mr G R Nagbushan
Mr Suyog panse
Mr Bisen Badal
Slide 2
7 Step QC story
Problem Solving Methodology
Step: 1 Define Project: Team Charter & Goal Statement
Mentor :
SR No
Team member
Contact no
Department
Mr. Gharat.R.V
Mr. Kulkarni.S.G
QA
Mr. Mhaske
QA
Mr. Karadi.S.B
Mr. Deshpande.R
APL
ERC
Mr. Pavan.K
8149095987
ERC
Mr. Asnikar.G
9881509735
ERC
Mfg
10
Mr. Diwakar.R
Mfg
11
8149059178
Role
7276045242
QA
ADD
Six Sigma
Slide 3
7 Step QC story
Problem Solving Methodology
Step: 1 Define Project: Action Planner
2013
Action planner
Feb
4
March
7
11
12
13
April
14
15
18
19
20
May
21
25
26
27
28
29
Plan
Team Charter
CFT formation
Act
Plan
GOAL Statement
Target Definition
Act
Data Collection
Plan
Act
PLAN
Plan
Data Stratification
Failed part s
analysis
Problem Definition
Deeper Analysis
Bench marking
Competitor products/
Process benchmark (min 3)
Cause Effect
Analysis
Ishakawa Diagram
Act
Plan
Act
Plan
Act
Plan
Act
Plan
Act
Plan
Act
Plan
Copyright, Confidential, Tata Motors Ltd
Action
Progress
Slide 4
7 Step QC story
Problem Solving Methodology
Step: 1 Define Project: Action Planner
2013
Action planner
FEB
4
DO
11
12
13
APRIL
14
15
18
19
20
MAY
21
25
26
27
28
29
Plan
Containment
Action
Verification &
Validation of
causes
3G Analysis
MARCH
Act
Plan
Act
7QC tool and 8D
methodology
Plan
Action
Check
Act
Plan
Verification &
Validation
Action
Implementation
Permanent corrective
action
Check Results
Act
Recurrence
prevention
Standardization
Horizontal deployment
Plan
Act
Plan
Act
Plan
Act
Plan
Act
Plan
Felicitation
Act
Plan
Copyright, Confidential, Tata Motors Ltd
Action
Progress
Slide 5
7 Step QC story
Problem Solving Methodology
FY12-13
Field IPTV
FY10-11
75
50
50
nos
nos
25
25
13
0
Dec-12
Jan-13
0
Jan-13
Sep-12
Jul-12
Aug-12
Dec-12
75
Jun-12
Jan-12
Dec-11
Nov-11
Oct-11
Sep-11
Aug-11
Jul-11
Jun-11
May-11
Apr-11
Mar-11
Feb-11
50
29
nos
50
Oct-12
Nov-12
May-12
10
Apr-12
nos
25
25
10
0
Nov-12
Oct-12
Sep-12
Jul-12
Aug-12
May-12
Apr-12
Jun-12
Mar-12
Feb-12
Jan-12
Dec-11
Nov-11
Oct-11
Sep-11
Aug-11
Jul-11
Jun-11
May-11
Apr-11
Mar-11
Feb-11
Jan-11
In-House Re
75
Supplier EOL
Mar-12
Feb-12
Jan-12
Jan-11
In Process
No data available
75
Take away: Detection adequate at Process, incoming stage for brake disc and hub defects.No failure of wheel cylinder at assly stage.
Copyright, Confidential, Tata Motors Ltd
Slide 6
IPTV
REAR
WHEEL
CYLINDER
BRAKE
DISC
82%
0.66
VACUUM
BRAKE
BOOSTER FIEXIBLE
HOSE
Compl Description
94%
0.66
BRK
LINERS
Aggregates
100%
71%
53%
1.99
0.66
0
40
40
20
3 mth
Jun/11
6 mth
12 mth
18 mth
17
3
2
Mar/12
Apr/12
May/12
1
0
2
Jul/12
Aug/12
Sep/12
Oct/12
Jun/12
20
Feb/12
26
11
11
16
26
22
19
15
3
Nov/11
25
18
Jan/12
Oct/11
Dec/11
Sep/11
33
41
41
Aug/11
18
71
64 75
65
69
66
60
77
62 70
56
53 66
61
May/11
31
28
32
2331
59
73
Jul/11
4 11
9
Apr/11
21
1823
39
1 10
Mar/11
28 39
2530
33
Feb/11
Dec/10
37
Jan/11
6 1016
41
43 54
59 70
57
Nov/10
1924
23 34
20 2935
Jul/10
0
Aug/10
3338
60
12
Percentage
80
Oct/10
8%
Sep/10
11
Brakes 6M IPTV
100%
99%
99%
97%
94%
91%
86%
80%
71%
63%
124
98106 122
124
120
6 15
141
140
Jun/10
May/10
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
Cmpls / 1000
Gear box
Chassis
Cooling
Axle
% Contribution
Suspension
Steering
HVAC
11
12
14
14 53%
40
Sumo
Brakes
Engine electricals
Engine
Clutch
43%
20
29%
45
40
35
30
25
20
15
10
5
0
Cab
Electricals
Cmpls (IPTV)
7 Step QC story
100
24 mth
120%
100%
80%
60%
1.33
40%
20%
0%
CALIPER
PAD
Slide 7
7 Step QC story
Problem Solving Methodology
Step: 2 : Observation:2.1- Data Collection
Model Wise Production Vs Reported Complaints (Brake Aggregates)
Period - JAN 12 To AUG 12
3500
17
19
22
No of vehicle produced
26
200
20
3000
11
150
16
2500
2000
100
11
1500
1000
No of Concerns
4000
Production Batch
6-Monthly IPTV
50
500
0
No of vehicle produced
No of complaints
JAN
FEB
MAR
APR
MAY
JUNE
JULY
AUG
3058
2890
2982
3221
3564
2393
1506
2979
58
65
61
55
93
39
17
33
Brake complaints shows down trend after June batch production by approx 40%
Copyright, Confidential, Tata Motors Ltd
Slide 8
7 Step QC story
Problem Solving Methodology
Step: 2 : Observation:2.1- Data Collection
SUMO BRAKE COMPLAINTS RECEIVED DEFECT WISE
Period - JAN 12 To AUG 12 production batch
350
120
250
77
82
86
90
92
94
95
96
97
99
98
100
100
80
70
200
59
60
150
100
40
31
Cum % Age
No of vehicle produced
300
20
50
0
Wheel
cylinder
leak/Sc
ored
Brake
disc
runout/
uneven
contact
Brake
vacuum
booster
all
defects
Brake
Brake
drum
master
scored/
cyl leak/
uneven
Scored
contact
Caliper
pad
worn/
Crack
Caliper
assy all
defects
Brake
liners
worn/
cracked
Parking
brake
cable
defect
No of complaints
314
276
112
71
50
44
43
24
cum % Age
31
59
70
77
82
86
90
92
Hand
brake
LCRV
Defectiv lever
e
knob
broken
Brake
pipe
crack/
Leak
Brake
line
connect
ors leak
Brake
Hose
crack/
Leak
ABS all
defects
23
17
94
95
96
97
98
99
100
0
Brake
fluid
contain
er/ leak
2
Top Four Brake complaints contributes 77% of total brake aggregates complaints .
Copyright, Confidential, Tata Motors Ltd
Slide 9
7 Step QC story
Problem Solving Methodology
Step: 2 : Observation:2.1- Data Collection: Front brake pad worn out
5.3
3.1
4.1
3.5
3.3
2500
15
1.2
2000
10
0.6
1500
1000
40
No of Complaints
3000
3.5
No of Complaints
No of Vehicle produced
3500
20
500
0
No of Complaints
35
30
25
20
15
10
5
0
No of complaints
% Age
APR
MAY
JUNE
JULY
AUG
3058
2890
2982
3221
3564
2393
1506
2979
11
12
10
10
19
60
40
20
Delhi
Bangalo
re
Pune
29
13
43
62
Deharad
Bijapur Mumbai Others
un
75
3
79
2
82
2
85
40
10
20
WEST
EAST
No of complaints
37
16
11
% Age
53
72
95
100
35
30
25
20
15
10
5
0
10
100
60
20
80
43
53
SOUTH
100
62
100
80
NORTH
100
No of Complaints
No of complaints
MAR
%Age
VEHICLE PR
FEB
72
30
0
JAN
%Age
4000
No of complaints
> 5K
5K-10K
10k-15K
15K - 20K
12
33
18
Slide 10
7 Step QC story
Problem Solving Methodology
Step: 2 : Observation:2.1- Data Collection :: Front brake pad worn out
PCR data received from Jan 12- Aug-12
Matrix Chart
Dealer
Analysis
Customer
Verbatim
Brake pad
Defective
Brake Hard
Brake Insufficient
% Age
5%
3%
10
19
27%
6%
25
31
44%
11
15%
100%
Brake Jam
Brake Noisy
11
Brake shuddering
Grand total
% Age
Uneven
Wear
Total
Brake Grabbing
Brake Pad
worn
out
53
71
7%
10%
76%
7%
100%
86 % Customer has reported Brake noisy , Brake insufficient & Brake Shuddering due to front brake
pad worn out.
76 % of complaints found that the friction material was completely worn out .
Copyright, Confidential, Tata Motors Ltd
Slide 11
7 Step QC story
Problem Solving Methodology
Step: 2 : Observation:2.1- Data Collection :: Front brake pad worn out
Matrix Chart
Failure
Mode
Brake Pad
worn out
Total
% Age
15
15
48%
13%
29%
Uneven Wear
10%
29
31
100%
6%
94%
100%
Dealer
Analysis
Grand total
% Age
94 % of complaints reported found that the friction material was completely worn out .
Slide 12
7 Step QC story
Problem Solving Methodology
Step: 2 : Observation:2.2- Under Standing
Process documents, drawings, Control Plans, WIS, DVP, DFMEA, Design Guideline
Dealer
Analysis
DESIGN CONTROLS
Sl No
DFMEA
Service Advisory
Document
8
Copyright, Confidential, Tata Motors Ltd
Slide 13
7 Step QC story
Problem Solving Methodology
Step: 2 : Observation:2.3- Failed part Analysis
Visual / On Test Rig / Vehicle analysis (Minimum 30 failed parts)
Dealer
Analysis
Visual
Inspection
OK
Pass
Test on
Vehicle
Fail
OK
Testing
on Test
rig
NOT OK
GAP ANALYSIS
Simulating testing
methods with Actual
customer usage.
DVP up-dation.
Identifying new test
methodology
Critical parameters
Measurements
Fail
Trials with
customer
support
Pass
Feedback to dealer through
CS
Slide 14
7 Step QC story
Problem Solving Methodology
Step: 2 : Observation:2.3- Failed part Analysis
16
16
14
14
Number of complaints
Number of complaints
12
10
8
6
4
2
12
10
8
6
4
2
0
0
Pads wornout
15
Concern observations
Level-2 Pareto for Brake pads Worn out & Uneven wear
14
Number of complaints
Number of complaints
4
3
2
1
12
10
8
6
4
2
Concern observations
15
12
29 number of incidents analyzed and found that friction material was completely worn out .
Copyright, Confidential, Tata Motors Ltd
Slide 15
7 Step QC story
Problem Solving Methodology
Step: 2 : Observation:2.5- Problem Definition
Brake
Brake
Grabbing
Hard
19
Brake
insufficient
31
Brake
Brake Jam
Noisy
11
Brake
Shuddering
Brake Pad
Defective
Brake pad
Brake pad
Brake pad
Brake pad
Brake pad
Hard/Glazed
Defective
Worn out
Hard/ Glazed
Worn out
Brake pad
Brake pad
Brake pad
Uneven
Brake pad
worn out
Worn out
Hard/Glazed
wear
Worn out
Brake pad
Uneven
Worn out
Wear
Uneven
wear
94%
6%
Brake pad
Brake pad
Worn out
Hard/Glazed
94% of complaint found that friction material on front brake pad was completely worn out .
Copyright, Confidential, Tata Motors Ltd
Slide 16
7 Step QC story
Problem Solving Methodology
Step: 2 : Observation:3- Understanding design, mechanism and functionality, benchmarking comparison at concept level
Pedal box Assembly
Brake pedal
Stop light switch gap
adjustment
Booster Assembly
Knuckle assembly
Disc
Caliper
Slide 17
7 Step QC story
Problem Solving Methodology
Step: 3 : ANALYSIS : 3.0- CAUSE EFFECT ANALYSIS
Caliper mount offset specification
Knuckle
HUB
Knuckle
Brake Pads
Firewall deflection
Higher surface finish value
Sluggish return
Improper grade selection
Brake system
Caliper
Brake fluid
DISC/DRUM
Front brake
pad worn out
Brake light switch improper adjustment
Rim/Tire modifications
Clevis pin tight
Aggregates Un cleaned
Environment Condition
Coastal Area
Excessive dust / Sand.
Vehicle Overloading
SUPPLIER
Customer Usage
TAXI/ Personnel
TML
Brake fluid contamination
Rainy
Service
Usage of non genuine spare parts
Slide 18
7 Step QC story
Problem Solving Methodology
Step: 3 : Analysis : Cause & Effect Matrix
Slide 19
7 Step QC story
Problem Solving Methodology
Step: 2 : Observation:2.4- Problem Definition
Brake pedal sluggish due to tight tolerances of clevis pin & pedal hole.
Poor performance & wear characteristics in City & Hilly region application
Slide 20
7 Step QC story
Problem Solving Methodology
Step: 2 : Observation:2.4- Problem Definition
Brake stop light switch adjustment with designed gap gauge implemented on production line from
March-2012.
As a Poke-Yoke new snap-on type brake stop light switch is designed. Implementation planned from
March -2013.
Mass added caliper (C57), is under validation with Wolverine shim with target residual drag of 50 kg
cm, against current 75 kg cm.
Implementation planned from May - 2013.
Brake pedal hold designed tolerances revised & implemented in production since June -2012.
R 808 friction pads are under validation for performance & wear.
Implementation planned from May 2013, along with mass added caliper.
Slide 21
7 Step QC story
Problem Solving Methodology
THANK YOU
Slide 22