CASE STUDY FOR DYNAMIC CONTROL PLANNING (Exercise for PFC, PFMEA & CP) MD of a reputed automobile OEM

planned to launch a new SUV (Sport Utility Vehicle), as competitor has introduced a new model in SUV category with latest technology of Drive line (Engine, Axle, Transmission). MD has issued a circular to declare APQP teams, Project Leader in various Axle, Transmission & Engine areas. For reducing total implementation period till job one and to meet market demand, final product design is bought from reputed design consultancy firm. APQP team leader asked to plan DCP as per the timing plan. APQP team leader collected data from JD power survey report, Warranty Report, Rework /Rejection data, TGR (Things Gone Right), TGW (Things Gone Wrong ) report for present model. Based on severity & occurrence top four concerns are identified. Following is the list of concerns in axle aggregate of present SUV as per ranking criterion. 1. 2. 3. 4. Premature failure of Differential bearings in Gear Carrier Assy. Pinion mate shaft failure in Differential Assy. Tyre wear Crack in axle welding between Yoke & Tube

APQP leader planned plant visit next day with QA manager to have an overview of manufacturing area. His intention was to eliminate all assy & machining errors during manufacturing process planing of a new model. He has started from receiving area. In receiving inspection at axle supply module an inspector was doing layout of Split Differential Case RH castings. He asked inspector about acceptance level & status. Inspector told him that castings & forgings are checked one per lot for layout & one is sent for lab report. Hardness is found OK as per Drawing specs. But he also informed that in Split Diff case RH last few months hardness variation is observed for one newly developed supplier (out of 3 suppliers) which may affect machinability & STA (Supplier Technical Assistance) team has already visited the supplier for resolving hardness issue , but concern is not yet closed. Supplier sends Castings of Diff Cases in metal boxes. Once clearance is given by inspector, lot is accepted & record is updated on SAP. Inspector checks part by Casting qualifying gage & layout method. Operator from machining cell loads all castings on trolleys & brings it near LMW CNC turning machine (#1720) . Leader & QA manager were very much curious to see turning as bearing dia was being machined on this machine. Warranty reports for Differential brg. failure was showing alarming trend. When leader was observing the opn.(#1720), he has seen other two maintenance operators also observing machine behaviour. When he has asked about machine, they replied that they have introduced work seat failure system for proper resting of part. Simultaneously they were checking pressure gage for set clamping pressure. Machine operator (# 1720) was cleaning the resting plate on chuck with high pressure air jet & holding part till it is clamped by jaws on first station. This is the first machining opn on RH Differential Case line where external machining is completed & inside machining is done on next LMW M/c (#1730) Both LMW machines are having facility of alarm to change the insert after 300th machined part.
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Mean while Cell leader came forward to meet QA manager and requested him to approve product deviation as bearing dias (on 1720) of split Diff RH were not under control due to fast insert wear. QA manager approved it provided 100% inspection is followed till proper quality inserts are made available by TMC (Tool Management Center). Normal frequency of checking diameter & face runout was 1 in 10 & X bar R bar chart was maintained. Leader asked cell leader about two trollys one was with plastic covered pipes & other one was with only metal pipes. Cell leader explained him that he receives casting on trollys with metal pipes and for finish turned parts he uses trolly with plastic covered pipes. He clarified that due to plastic pipes brg dias are not damaged during transportation for taking it to inspection station where Dial snap gages for diameters & qualifying gage for linear dimns are used for inspection. QA manager also shown fishbone diagram (Root Cause Analysis refer attached sheet) made by CFT to resolve the concern Next opn. was boring opn. of 4 holes of 19.035 +/-0.015 mm 90 deg.+/- 0 deg 1 min apart. Gear Carrier assy officer was discussing with Cell leader about jamming of side gear pinion mate. He had done all permutations & combinations of OK/NOT OK parts and concluded that some thing is wrong in Diff Case. Both the officers checked 4 holes position with qualifying gage. Assy officer also wanted to confirm X bar -R bar chart for diameters displayed on HMT boring machine (#1049) because some assy operators had complained many times about pinion mate shaft pressing is difficult & press shows more tonnage than required (2 Ton). There were some cases with loose fitment of shaft. Assy officer told all jerky assemblies are detected at assy stage & not going to external customer but his stage rejection has increased to 5% . Machine operator brought dial to confirm spindle runout as if it goes beyond 0.010 mm , parts shows more variation on bore size. Assy officer while leaving the dept. asked Cell leader to ensure cleaning of chips below part before loading for boring opn. Also he has suggested to increase frequency of diameter checking to 1 in 10 from 1 in 20. Before leaving machining cell, leader asked cell incharge what does operator do if part gets rejected. He replied that all operators are trained. Rejected parts are kept at quarantine area & tool is reset to bring it to mean. On the way to Gear Carrier assy APQP leader has seen one Differential Case is brought on trolley. QA manager informed him that we check one part per shift for surface finish on perthometer and angle between Holes on CMM (Co-ordinate Measuring Machine). This responsibility is with QA person. After boring opn parts are taken to final inspection stage. Then all parts are cleaned in OMICRON washing machine (#1820) & kept ready for Gear Carrier assy. Then assy operator collects parts as per the requirement. APQP leader left for meeting with CFTs for updating them for various inputs. APQP leader started his activity from axle aggregate & declared CFTs for each aggregate. He has briefed observations to all members of the CFTs and asked them to prepare DCP as per the timing plan.

Note: 1) Candidate should assume data if required. 2) Gages / standard inspection instruments are available at work station.
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