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Preamble
1
1.3 Importance of the problem
TVS Motor (TVSM) confirmed their production ramping up plan during
the third quarter of 2011- 12. TVSM has demanded for the cost reduction of the products due
to the increase in the quantity of production also.
1.3.1 Need for study
We are supplying two wheeler seats to our prestigious customer TVS
motor company located in Hosur & Mysore with 100% business share for the year 2000
onwards .The supplies are made on just in time (JIT) basis every hour .The business with them
has been consistently growing since then from 2,700 seats per day in the year 2002-03 to 6,400
upto 2009-10. The projected volume for 2011-12 is 8,400 seats per day .So from the projected
volume we got a hint that DOE in this area will definitely give a cost optimization there by
benefiting the organization. `
2
TV S M R e q u ir e m e n t / d a y
9000 8400
8000
7000
6000
6000
5000
Seats in nos
4423
4038
4000 3462
2692 2885
3000
2000
1000
0
Y ear 2005- 06Y e ar 2006-07Y ea r 2007-08Y ear 2008-09Y ear 2009- 10Y ear 2010-11Y ear 2011-12
200
Qt
y
0
160 200
150
0 0
120 0
0 900
700
800 600 600 500 500 400 400
300
400
0
Ma
Star XLHD Star XLN U68 N45 XL - N90 N17 U41
x
Sport Dlx 100 HD
Model wise
3
1.4 PRIMARY OBJCTIVE
The main objective of this project is to find the optimal method of two-wheeler seat
assembly using Design of Experiment (DOE).
4
Harita Seating Systems Limited (HSSL) (Formerly known as Harita
Grammer Limited) is an automotive ancillary unit situated at Belagondapalli village near
industrial town of Hosur, (A Suburb of Bangalore) Tamilnadu.
Grammer AG’s (GAG) success story can be traced back to 100 years
(1880), when Mr Willibald Grammer opened a saddlery in Amberg,
Germany. Mr George Grammer, his grandson, expanded the saddlery
to an industrial manufacturing plant. Starting in 1954 with cushions
for tractor seats, by 1964 GAG entered the era of modern seating systems, supplying
suspended seats for agricultural tractors, construction machines, and material handling
equipment. Today, GAG is one of the leading suppliers of seating systems world over. GAG
group comprises 40 facilities in 19 countries around the globe, with group turnover exceeding
1.3 billion-DM.
5
Harita Seating Systems Limited (HSSL) is a complete solution provider for seats
and seating systems for both automotive and non-automotive applications. HSSL
manufactures, driver seats for commercial vehicles, buses, tractors, off-road vehicles, cars,
multi-utility vehicles, two wheeler and three wheeler segments; passenger seats for buses,
cars, multi-utility vehicles and three wheeler segments; and seating systems to the railway and
auditorium segment. The company also offers products for automotive industry through
polyurethane composites Established in 1986; HSSL commenced its commercial production
in 1988. Today HSSL has established itself as the leader in development & manufacture of
innovative seats & seating systems for the commercial vehicles, buses, tractors & off-road
vehicle industry. HSSL recorded turnover of Rs 194 Cr in 2007-08.
During the year 2008-09, the company acquired Polyflex Group of companies. Through this
acquisition, the company has paved the way for entry as a Tier-2 polyurethane foam supplier
to reputed customers like Hanil Lear in Chennai, Tata Johnson Controls and Lear in Pune and
Chennai, and Toyota Boshoku in Bangalore. The foam pads supply will go into the cars of
Hyundai, Tata Motors, Ford, Mahindra Renault and Toyota Kirloskar
6
Segment / Product Customers
Fig 2.2.1a
Telco, Hindustan products
Motors, and customers
San Motors, Reva Electric Car Co ,Internationl cars
Cars & MUV seats
and multi utilility vechiles.
TAFE, M&M, Escorts, New Holland, Same Greaves, L&T John Deere,
Tractors
Eicher,
HMT, International Tractors
Sate Transport Undertakings , Body Builders and major fleet operators across
Bus Passenger seats
The country , VOLVO , Mercedes Benz , Tata Marcopolo , Swaraj Mazda
8
Unit IV Nalagarh
Unit III
Jamshedpur
Unit II Ranjangaon - Assembly unit
Chennai
Unit I- Hosur - Registered office
.
Manufacturing facilities at Hosur and Ranjangaon includes
9
1. Modernized Polyurethane Cushion manufacturing unit.
6. Assembly cells
President
Research
Manufacturi Personnel Business
& Purchase Marketing Finance Quality
Development ng & TQC Planning
10
2.3 Sales Trend of Organization
191 192
200
Rs. in Crores
150 130
114.1
98.3
100 76.6
58.3 60
50.2 50
41.7 42.4 43.2
50 27.5
0
'00- 01
'01- 02
'02- 03
'03- 04
'04- 05
'05- 06
'06- 07
'07- 08
'08- 09
95- 96
96- 97
97- 98
98- 99
99- 00
'09- 10 Est
Fig 2.3 : Sales trend of organisation
The company has planned to exceed Rs 250 Crores sales in the next financial year
2009-2010. The company has added products, technology and closely nurtured culture of Total
Quality Management (TQM) pillared by Policy deployment, Kaizen, TEI, Training and
Standardization. The management focus this year on cost reduction under the circumstances of
stiff competition and price war in the market through alternate material, alternate processes,
and waste elimination and productivity improvement projects and also through stringent cost
control measures.
11
2.4 Milestones
2009
Water management
Excellent water efficient
2007
unit
Energy management
Energy conservation
2005
award
Occupational Health and
Safety
2004
OHSAS 18000
Co pro
Manufacturing systems
ACMA manufacturing
im
2003
excellence
Quality management
systems
2001
ISO/TS 16949
Quality
management
2001
ACMA Quality
award
Environmental
management
2000
ISO 14001
2007
Management
systems
1999
systems
Energy management
QS 9000
1996
Energy conservation
Manufacturing systems award
ACMA – Productivity
award ACMA – Automotive Component Manufacturers Association of India
CII – Confederation of Indian Industries
13
3.0 Identified problem
3.1 Introduction
In the present period of recession prevailing in all parts of the world, the company
has to manage all the tough situations and be a leader in the market by concentrating on the
following
Productivity
Quality
Cost
Delivery
Morale &
Waste elimination
Also, Indian Economic Reforming policies demand companies to improve their Quality,
Productivity, Cost, and Delivery requirements continually. Continuous Improvement should be
present in the every aspect of the business, without which the companies cannot survive in the
present competitive market.
Particularly after globalization and liberalization, Indian companies are facing stiff competition
and threat from companies of other Countries.
To achieve the business growth, customer delight becomes the prime focus for which the
above said 6 parameters need to be improved to world class levels.
HSSL is the major source to TVSM and the share of business is 100 %. The supplies are made
on Just –In-Time (JIT) basis every hour.
The customer requirement has been consistently growing every year.
Overall Two wheeler segments in India are growing year to year and recorded a growth of
minimum of 20 % consistently. But the contribution values of the two wheeler seats are very
low. This was the main reason to concentrate in this project.
Based on the projected volumes for the year 2009-10 to the tune of 250 Cr, our company has
formulated the following objectives and guidelines.
14
Guidelines for 2011-12
Improve productivity through constant/ continuous re-engineering the manufacturing
processes
Design of Experiment (DOE) for materials cost reduction
Apply value engineering (VE) technique for low contribution products
Explore alternate materials for cost reduction
Implement low cost automation (LCA) projects
New technologies for product and process.
JIT supplies to customers
Flexible Production
Bench marking
Lean manufacturing
3 M elimination
Standardisation
Implement waste elimination projects through TEI
Based on the guideline no. 1 & 2, this project is taken up for implementation.
15
% of the quantity.
140000 120
119800 100.0
120000 91.4 91.6 100
86.6
80.7
100000
80
65.4
80000
Quantity
% Cum
60
60000
40
40000
27980
20000 15421 20
10813 8777
404
0 0
TW LCV Tractor BPS Car Others
Segments
HSSL has started supplies of two wheeler seats to TVS Motor Company (TVSM),
10000
8400
7500
6000
Nos / day
5324
5000
2500
0
HSSL Current capacity TVSM Current demand TVSM Projected dem and
16
Hosur and Mysore in a big way since March 2000. The business with TVSM has
been consistently growing since then from 2,700 seats per day in the year 2000 – 01 o 5,000 up
to 2007-08. The projected volume for 2011-12 is 8000 seats per day.
At present, with the increasing trend of the production volume, the contribution of the two
wheeler seats are low due to the increasing prices of the raw materials. Various proposals have
been made to reduce the cost of the seats by using value engineering techniques and usage of
alternate materials in line with our policy objectives and strategies.
62.0
Quantity
% Cum
9634
10000 60.0
43.8
40.0
4992
5000 23.6 4400
3816
3097
20.0
1992
1200 960
482
56 24
0 0.0
TS
R
Y
LX
X
68
40
90
27
45
41
TO
IT
lH
AM
R
N
G
M
C
IC
H
R
V
TA
S
R
S
TA
Model
S
The objective of this project is to develop the optimal method in the material composition of
Two wheeler seat assembly using design of experiments which reduce the material cost by 1 -
3 % and improve the contribution value from 20% to 22%.
17
3.3 IMPORTANCE OF THE PROJECT
25
22 22 22
20
20
18
17
15
10
0
Star Sport Star city XLHD
Our customer TVS Motor confirmed their production ramping up plan during the First
quarter of 2011 – 12. TVSM has demanded for the cost reduction of the products
Due to the increase in the quantity of production also. We have drawn a bar chart showing the
existing and planned contribution of 4 running products as per the policy matrix.
From the above graph it is clear that we have to bring down the material cost / manufacturing
cost of the products like Star Sport, Star city and XL - HD
18
A comparative study has been done based on the weight of the cushions running
in the Two Wheeler Foaming Line. Based on the study, we have prepared a chart with the
weight of the components have found that Star Sport model was contributing around 25 %
of the total chemical consumption. Taking this for improvement will contribute in high cost
benefits.
28
21 20.16
17.64
Tons
14
10.37
7.8
7 5.3
4.32
0
Star Sport Victor Star CityProduct
Scooty Pep Victor GLX Sccoty Teenz
19
To optimize the weight of the PU Foam, the company has adopted a technique called
Idea Simulator.
Table 3.1. Idea Simulator for Star Sport foam
20
Based on the discussion held by various department heads for idea simulators it gave us a
positive approach to look for alternate ideas. In the case of Star Sport model, we are optimise
the weight of the PU Foam triggered a good potential for cost benefit as well as customer
complaint elimination.
Taking into account of idea simulation the Star Sport foam hinted a good potential of
material removal without disturbing the basic functionalities benefiting the organization cost
wise.
4. REVIEW OF LITERATURE
4.1 Design of Experiments
In order to benefit the organization by DOE where the problem is dealt with the
following techniques to eliminate the seat rejection; the techniques will definitely show a
positive trend in PPM as well as rejections. Overall the objective of the organization is taken
care in all aspects in terms of delivery, quality and cost.
DOE is a structured, organized method for determine the relationship between factors
(X) affecting a process and the output of that process (Y) while using minimum number of
experimental runs.
Types of DOE
1. Factorial Experiment Design
a. Full Factorial
b. Half/one fourth / one eighth Factorial Design
c. Screening Design
2. Taguchi Approach
3. Central Composite Design
During the improvement of products and processes, there are different “knowledge levels”
starting from a scarce knowledge to a deep knowledge.
21
Introduction
Experimental design can be used at the point of greatest leverage to reduce design
costs by speeding up the design process, reducing late engineering design changes,
and reducing product material and labor complexity. Designed Experiments are also
powerful tools to achieve manufacturing cost savings by minimizing process
variation and reducing rework, scrap, and the need for inspection.
This Toolbox module includes a general overview of Experimental Design,
instructions and templates for conducting simple experiments, and links and other
resources to assist you in conducting more complex experiments. A glossary of
terms is also available at any time through the Help function, and we recommend
that you read through it to familiarize yourself with any unfamiliar terms.
Preparation
If you do not have a general knowledge of statistics, review the Histogram, A class
main link heft"http://www.moresteam.com/toolbox/t404.cfm "Statistical process
Control, and Regression and Correlation Analysis modules of the Toolbox prior
to working with this module.
Although you can use the MoreSteam.com DOE spreadsheet templates to analyze
several experimental designs using Excel or lotus, you will need statistical analysis
software to go beyond these basic experiment design templates. Several free
packages can be downloaded through the MoreSteam.com Statistical software
module of the Toolbox. In addition, the book DOE Simplified, by Anderson and
Whitcomb, homes with a sample of excellent DOE software that will work for 180
days after installation.
Purpose
Designed experiments have many potential uses in improving processes and products, including:
22
Comparing alternatives. In the case of our cake-baking example, we might want to
compare the results from two different types of flour. If it turned out that the flour
from different vendors was not significant, we could select the lowest-cost vendor. If
flour were significant, then we could select the best flour. The experiment(s) should
allow us to make an informed decision that evaluates both quality and cost.
Identifying the Significant Inputs (Factors) Affecting an Output (Response) -
separating the vital few from the trivial many. We might ask a question: "What are the
significant factors beyond flour, eggs, sugar and baking?"
Achieving an Optimal process Output (Response). "What are the necessary factors,
and that are the levels of those factors, to achieve the exact taste and consistency of
Mom's chocolate cake?
Reducing variability. "Can the recipe be changed so it is more likely to always come
out the same?"
Minimizing, maximizing, or Targeting an Output (Response). "How can the cake be
made as moist as possible without disintegrating?"
Improving process or product "Robustness" - fitness for use under varying conditions.
"Can the factors and their levels (recipe) be modified so the cake will come out nearly
the same no matter what type of oven is used?"
23
Reference : II
http://www.ee.iitb.ac.in/~apte/CV_PRA_TAGUCHI_INTRO.htm
TAGUCHI Method:
Dr. Taguchi of Nippon Telephones and Telegraph Company, Japan has developed a method
based on “ORTHOGONAL ARRAY” experiments which gives much educed “variance” for
the experiment with “optimum settings” of control parameters. Thus the marriage of Design
of Experiments with optimization of control parameters to obtain BEST results is achieved in
the Taguchi Method. Orthogonal Arrays" (OA) provide a set of well balanced (minimum)
experiments and Taguchi's Signal-to-Noise ratios (S/N), which are log functions of desired
output, serve as objective functions for optimization, help in data analysis and prediction of
optimum results.
Generally, a process to be optimized has several control factors which directly decide the
target or desired value of the output. The optimization then involves determining the best
control factor levels of that the output is at the target value. Such a problem is called as a
"STATIC PROBLEM".
This is best explained using a P-Diagram which is shown below ("P" stands for Process or
Product). Noise is shown to be present in the process should have no effect on the output!
This is the primary aim of the taguchi experiments - to minimize variations in output even
though noise is present in the process. The process is then said to have become ROBUST.
24
2. DYNAMIC PROBLEMS
If the product to be optimized has a signal input that directly decides the output, the
optimization involves determining the best control factor levels so that the "input signal /
output" ratio is closest to the desired relationship. Such a problem is called as a "DYNAMIC
PROBLEM".
This is best explained by a P-Diagram which is shown below. Again, the primary aim of the
Taguchi experiments - to minimize variations in output even though noise is present in the
process- is achieved by getting improved linearity in the input/output relationship.
25
STEPS IN TAGUCHI METHODOLOGY:
STEP-1: IDENTIFY THE MAIN FUNCTION, SIDE EFFECTS, AND FAILURE MODE
STEP-2: IDENTIFY THE NOISE FACTORS,
TESTING CONDITIONS, AND QUALITY CHARACTERISTICS
STEP-3: IDENTIFY THE OBJECTIVE FUNCTION TO BE OPTIMIZED
STEP-4: IDENTIFY THE CONTROL FACTORS AND THEIR LEVELS
STEP-5: SELECT THE ORTHOGONAL ARRAY MATRIX EXPERIMENT
STEP-6: CONDUCT THE MATRIX EXPERIMENT
STEP-7: ANALYZE THE DATA,
PREDICT THE OPTIMUM LEVELS AND PERFORMANCE
STEP-8: PERFORM THE VERIFICATION EXPERIMENT AND PLAN THE FUTURE
ACTION
Full Factorial
4 Design Programme of Fractional
Replication
Randomization Experiments Factorial
Repetition Screening
Taguchi
5 Collect Data
Graphs
6 Analyze and Interpret Results Regression
ANOVA
7 Verify Results
8 Return to 3 as necessary
26
Table 4. 1: – Design of Experiments Approach
Level of Knowledge
variables)
Optimization
2-4 Full Factorial
(Deep investigation for few
variables and their
interactions)
4.3 METHODLOGY
In this project, the following methodologies are adopted to find the optimal
method of two –wheeler seat assembly (Foam cushion area) using Design of Experiment.
• Study of the current process
• Usage of Design of Experiment Techniques
• Adaptation of DOE concept
• Literature survey on DOE process in change process
• Prepare questionnaire to understand the issues involved in the change process.
• Implementation and Standardization
• Trail running with the change process to measure the outcomes
• Collection of data by experiments
• Analyze the data collected thro quality tools
• Conclusion
27
5.0 DATA COLLECTION AND ANALYSIS
5.1 TYPE OF DATA NEEDED
In order to achieve cost reduction by DOE in the two wheeler seat to improve the contribution,
we have collected the following data.
• Customer complaints pertaining to Star Sport
• In-house rejection trend of Star Sport
• Current process parameters of Star sport cushion manufacturing.
• Quality standards for cushion manufacturing.
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
'09 '09 '09 '09 '09 '09 '09 '09 '09 '10 '10 '10
12 22 15 9 16 18 20 25 18 10 11 13
28
Fig 5.1.1.a: Customer complaint due to Seat High Hardness–Year wise
Fig 5.1.1.b.: Customer complaint due to Seat High Hardness– Month wise
30
25
Fish Bone Diagram for High hardness
20 29
There are many various reasons for High Hardness in foaming process. Brain
storming session conducted with employees and the reasons are correlated each other
using Fish Bone Diagram.
MAN MACHINE
Machine setting
Untrained Operator improper
operator negligence
Input Chemical
Importance not variation
known
High
Hardness
Effect: 100%
Improper
Chemical
Mixing Ratio No proper
Input Chemical traceability
problem No proper pouring
method
MATERIAL METHOD
30
Hence to eliminate seats getting rejected it is always necessary to go for a
DOE project, thus giving a potential for benefiting the organization
5.1.2.In-house rejections
Cushions are checked for its properties like hardness, profile, shape and
other surface defects. The parameter hardness predominantly contributes towards the seat’s
comfort level.
Testing of hardness is done as per IS 7888 for 4 wheeler cushions and JIS
6401 for Two wheeler cushions. Hardness testing will be carried out regularly to ensure
conformance to the specification.
If the manufactured cushions are not meet the quality standards it is
booked as In house rejection and moved to scrap area.
The below In house rejection data which is taken from SAP from April 2009 to March
2010.
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
'09 '09 '09 '09 '09 '09 '09 '09 '09 '10 '10 '10
8 12 6 9 15 11 16 9 13 10 8 13
250
220
200 180
155
150
100
50
0 31
07 - 08 08 - 09 09-10
Year
Fig 5.1.2.a.: In House Rejections–Year wise
Fig 5.1.2.b: In house rejections due to Seat High Hardness– Month wise
20
5.2. SOURCE OF DATA
Various sources for the types of data identified above are
a. Process flow diagrams can be collected from the Cushion Production on the basis of the
15
Process layout.
b. Operation standard formats can be received from the Plant Engineering
c. Customer complaint and in-house rejection details from our QAD.
d. Chemical consumption and production volume details from our SAP system
e. Test report from Quality Testing Department
10
Following are the collection of data for
ty
32
1. Customer complaints
2. In House rejections
3. Production Quantity
This Production quantity data has been collected from our Foaming Production
department from April 2009 to March 2010.
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
'09 '09 '09 '09 '09 '09 '09 '09 '09 '10 '10 '10
12571 9695 15574 16138 15368 20524 19724 16226 9451 8620 12226 16600
In addition the following data also collected for supporting the analysis.
6. PU Foaming Process
The term "POLYURETHANE" is used to describe any polymer that has been chain extended
by reaction with di or poly-isocyanate. In other words "POLYURETHANES" are polymers
formed by the polyaddition of polyfunctional isocyanates with compounds containing at least
two hydroxyl groups.
The term polyurethane is derived from the "URETHANE" group that is predominantly
formed in the reaction. A urethane group is formed by the chemical reaction between an
alcohol and an isocyanate. The isocyanate group (-NCO) can react with any compound
containing 'active' hydrogen atoms. (Active hydrogen atoms are those which react with a
Grignard's reagent, generally methyl magnesium iodide to give methane.)
The typical reaction that depicts the formation of polyurethane’s (PU) is given below:
Polyol + water and/or Polyisocyanates or POLY
The two wheeler cushion production unit consists of the following machines and equipment
34
Fig 6.1 High pressure reaction moulding machine
2. Linear carousel
The linear carousel is nothing but a closed loop telescopic conveyor chain
fitted with a caterpillar drive and used to move the mould carrying fixtures. The movement &
the speed of the conveyor are controlled through a control panel and an automated lubricator
unit ensures the smooth movement of the conveyor. There are 14 moulds carrying stations or
otherwise called as Mould Fixtures (MF), individually operated through hydraulic power
pack. The mould carrying stations are locked with the towveyor chain conveyor through
towing pins. The power supply is given the MFs through an overhead 4-line bus bar.
3.Moulds
35
Moulds are used to produce PU cushions. The moulds are CNC machined to obtain
the contour of the cushion and made up of Aluminium. Different varieties of mould cavities
are used for various products. We have about 20 varieties of two wheeler moulds.
There are 14 moulds with each with twin cavity are mounted in the mould carrying
stations. Each mould consists of top and bottom cavity. The top cavity is mounted in the top
frame of the MF by means of T bolts and the bottom cavity is fixed to the base frame of the
MF by means of conical locators. Hot water connection is given to the moulds to maintain the
mould temperature always between 55 – 60 degrees centigrade.
The injection head is the important part of the machine where is both Polyol
and Isocyanate are mixed thoroughly inside the chamber at a high pressure of 160 – 180 bar
and the laminar flow is created inside for homogenous mixing through the injection nozzle.
Then the homogenous mixture is injected into the mould. The rotary arm consists of a pillar
support, rotary base, pivoted arm with a counter weight and the moving arm where the mixing
head is mounted. The movement of the mixing head is achieved by means of a robot.
Each type of cushion requires certain type of machine setting depend on the size, hardness,
weight and other requirements. These settings are stored in the PLC of the machine .
RFID will activate the signal to the foaming machine thro the sensors, The machine has the
input details and gives the signal to the control panel of the Robot , Each individual moulds
having individual program stored in the control panel of the machine. The Robot gets the
input details from the Control panel of the machine and pouring of the chemical in the mould
cavity.
36
Cushions are checked for its properties like hardness, profile, shape and other surface defects.
The parameter hardness predominantly contributes towards the seat’s comfort level.
Testing of hardness is done as per IS 7888 for 4 wheeler cushions and JIS 6401 for 2 wheeler
cushions. Hardness testing will be carried out regularly to ensure conformance to the
specification.
6.1 Conclusion
Following points are taken care during the data collection.
1. Data collected is done from normal sales taking place in the organization ensuring the
desired range of sales trend is covered.
2. In house rejection trend is formulated from the actual data entered in the in house
software for daily monitoring.
3. Much care has been taken to ensure unbiased data collection during the entire study in
order to achieve reliability.
The collected data has been formatted and are further used for analysis.
37
1. Reduction in weight of the base chemical in Star Sport Cushion by DOE
We have taken the present process parameters, specification and observations of the Star Sport
cushions.
7.1 Present Process Parameters of Star sport cushion
Hardness : 11 - 15 Kgf
Hysterisis : 26 - 28 %
ISO : NE 134
Polyol : NF 755
38
Process Parameters
Local control Factors for DOE
1. Injection Time
-
2. ISO Qty
-
3. Injection Pressure ISO/Polyol
-
4. Mould temperature
-
5. Release agent application
-
6. Mould
- -
7. Component Temperature
-
Factors Levels
39
Table 7.1.1.a – Experimental Combination of
injection time & ISO quantity
We have used the ANOVA table to find the significance between the different setting and the
cushion hardness.
40
Cushion hardness is checked using the Hardness Test as per the Quality Standard
of Japanese Industrial Standards (JIS 6401). As per the Specifications the hardness should
be 11 – 15 kgf.
ISO Qty
78 80 82 84 86
3.15 8.8 9.2 10.8 12.4 14.8
3.25 10.2 10.8 11.2 12.7 15.2
Injection
Time in
3.35
secs
Total 177.76 24
Both Injection time & ISO Qty are significant for Hardness. (F value > F critical)
700
705
680
Weight in gms
669 670
660
661
640
641
620
600
3.15 x 84 3.25 x 84 3.35 x 80 3.35 x 82 3.55 x 78 3.55 x 80
Trial Combination
Figure 7.1a – Average Response of Weight – Star Sport Cushion
41
Average Response on Hardness
17
14 13.7
13.1
Hardness
12.7
12.5 12.4 UCL
12.1
11
LCL
8
3.45 3.45 3.55 3.35 3.45 3.55 3.45 3.25 3.15 3.35 3.45 3.55 3.55 3.35 3.25 3.55 3.15 3.35 3.35 3.25 3.15 3.25 3.25 3.15 3.15
x 86 x 84 x 86 x 86 x 82 x 84 x 80 x 86 x 86 x 84 x 78 x 82 x 80 x 82 x 84 x 78 x 84 x 80 x 78 x 82 x 82 x 80 x 78 x 80 x 78
Trial combination
Parameters
Existing
identified
process
30.4 during
experiments
parameter
30
29.8
Hysterisis in %
28.5
27.2 27.1
27
24
3.15 x 84 3.25 x 84 3.35 x 80
Figure 7.1.3c– Average Response3.35 x 82
of Hysterisis 3.55 x 78 3.55 x 80
Trial Combination
42
7.1.5. Trial Result
After the following trials, we found that the Hardness, hysterisis property
which is the main parameters was satisfied at the weight of 670 Gms. So, we have set the ISO
quantity at 82 Gms / sec and Injection timing at 3.35 and done the process capability and
found the hardness was within specification.
By the application of DOE process we found the optimum method of
Injection time 3.35 sec with the chemical combination of ISO quantity of 82 Gms/sec
By implementation of the project, we were able to reduce the weight of the
Cushion by 5 %
43
Figure 7.1.4– Testing and Proving
44
7.2. Standardisation
List of activities carried out towards standardisation of this Project.
45
To meet the above demand, following activities were implemented.
750 5 % Reduction in
weight
705
Weight in gms
700
675 670
650
600
Actual Plan Achieved
Figure 8.0– Plan Vs Actual
46
After standardizing the above activities in the regular production, we could achieve the
following benefits
A. Achieved cost saving of Rs 5.12 Lakhs per annum (Break up details given below)
Cost Savings through DOE in Star Sport Seat -Rs. 5.12.00 Lakhs
This improvement has been planned to be horizontally deployed to all similar products. The
target for implementation is during MAY ’11.
9 Conclusions
This project work has given very good information on the usage of the major tools
like Design of Experiment, ANOVA, Idea simulators etc., It has also provided me knowledge
on the PU Foaming Process.
This project yielded gains in terms cost, quality, delivery, time, etc., which we
have discussed in detail in section 8. Apart from the above, this project also provided an
opportunity to understand the PU Foaming Process and also implementation of projects in
practical at field and overcoming the difficulties and consequences faced. Benefit and
improvement gained out of this project has also motivated to improve my skills in problem
solving techniques.
9.3 LIMITATIONS OF STUDY
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Similar study can be extended to the other products in the organization where
there is a real need of the cost optimization
10. CONCLUSION
This project has given me immense confidence to handle similar projects in the other
areas.
It has enhanced my knowledge on usage of Design of Experiment.
This project has benefited the organization in terms of cost reduction to the tune of Rs. 5.12
lakhs / annum.
“Insect eye view” to any problem or an activity always improves the performance and
utilization.
Tools followed like ANOVA, idea simulators has helped to detect early failures of the system
and also provided opportunity to focus on accident prevention. This also helped in team
building by involving many people in the organization to use those tools.
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11. REFERENCES
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ACKNOWLEDGEMENT
I also wish to thank all my colleagues in my department for their valuable inputs during the
project.
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