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ACE Engineerings and Chemicals Pvt

Ltd
SIA ACTIVITY
Dec13

Signed Hoshin Kanri


Co-operation Team Supplier Improvement Activity Plan in ACE Engineering

Quality Goal
To reduce ppm level to 150 PPM by
2014 end

#
Zero defect at customer end
#

Continual improvement in process


through Poka-Yoke & Kaizens

Facilitator
Leader
Co-ordinator
Materials
QA

VECV Team
Mr Tomochi Katsumata
Mr Vinayak Shanbagh
Mr Yogesh Jagtap
Mr Jeetendra Joshi
Ms. Neha Jain

PDD

MD & CEO
Head-Manuf.
Head-Design
RQC
In process Quality

Mr. Amarjeet singh

Supplier up-gradation Mr. Vinay Singh

Controlled KPI -Ace Engg.


Tgt. Tgt.
Main Obje
KPI
Issu ctive
2009 201
Respons
Item
e Nam
(Base) 2 2013 2014 ible
s
e

Activity

Deli
Deliv
very PPM ery
Qual Impr PPM
11575 350 200 150
ity ove impr
PPM ment ove
wise
ment

Tool Room

Mr. Rajesh Dixit

Watched KPI - Ace Engg.


Responsible &
Supporting Department
Target 2013
Base
Respo
Tool
KPI Items
(2012
Desig
purch
Q1 Q2 Q3 Q4 nsible Prod
roo QC
Q4)
n
ase
m

3747 3000 2500 200 1500

Calibration

In-house monthly Process


PPM

4000 3800 3500 3200 3000

MSA

In-coming monthly PPM

1950 1800 1700 1600 1500

No of DOL parts
(Total 68 parts)
PDI Execution (% of PDI
followed invoices/Total
invoices raised)

Poka Yoke Process audit (No of parts )

61

62

63

65

66

100

100 100 100 100

Layout inspection (No. of


parts)
IMTE and Gauge Calibration

SIA Monthly Review PPT

Mr. Mayur Ajmera

In-house monthly PDI PPM

Process
Audit

CFT

PDI

Start
QRQC

5S

Supplier Team
Mr. Pradeep Jain
Mr. Manoj Ohja
Mr. Ramkaran Meena
Mr. Mayur Ajmera
Mr. Mayur Ajmera

102 21
-

Tooling validation (Dies, Jigs


& Fixture validation &
10
0
Maintenance)
Poka Yoke
12
3
QS Sign off
_
_
System audit score
81%

29

19 18

5
5
6
40 28
95%

5
6

ACE ENGINEERINGS & CHEMICALS PVT.LTD.


Monthly Internal Hoshin Kanri Review MOM with top management
S.
No
.

Date

5/12/13

2 12/12/13

Location

Issue

Analysis

Action

Target Dt. Complet


ion Dt

VECV

Due to improper adhesiveness of


insert on pp part cover plate assy.
Cover plate
Adhesive My-T Bond grade
Insert comes out; the adhesive
103 is used & tested as per
assy
used acra-bond shows poor
pull out test.
rejection
compatibility with the part
material.

VECV

GSC IA303087 Rejected mould were used by


- C.C
production dept, only 2 mould were Each part checked at
Dimension is OK and rest were rejected due to
FG,filing,painting,moulding,re
out by 9-10- which ok & not ok parts were found at worked with providion of
17/12/13
mm due to
VECV as well as FG Stock. Drilling
drilling fixture. New mould to
which fitment done by seeing marking which is very be provided with pin provision
issue
light due to which c.c varies is also the for further production.
occurred.
source of variation.

SIA Monthly Review PPT

7/12/13

Resp.

7/12/13

17/12/13

Mr.Laxman
Surage

GY
R
stat
us

ACE ENGINEERINGS & CHEMICALS PVT.LTD.

Monthly Internal Hoshin Kanri Review MOM with top management


S.
No
.

Date

3 22/12/13

Location

vecv

SIA Monthly Review PPT

Issue

Analysis

Action

It is seen that the gap of 15-25 mm


found after fitment of the part on
Sample (3) provided to VECV as
Gear shift cvr line. When checked dimensionally
per fitment basis. Waiting for
IA209914 gap height found 409-415 mm against 412
feedback for changes from
issue.
mm. Although part as per drawing has
VECV.
also resulted in gap from chamfer
side.

Target Complet Resp. GYR


Dt.
ion Dt
status

5/1/14 TBP

vecv

Control KPI
Controlled KPI :Targets VS Actual
S. No.

1.

Main
Issue

Objective
Name

KPI Items

Status

13Apr

13May

13Jun

13- 13- 13- 13Aug Sep Oct Nov

Dec

250 250 200

200

200

682

133

13Jan

13Feb

13Mar

TARGET

325

325

325 300

300 300

250

ACTUAL

49

939

96

606

756 200 90

13-Jul

Remark
s
13-

Delivery
PPM
Quality
Delivery PPM
Improveme
PPM
improvement
nt
wise
39

79

KPI Summary
Months

MarchApr-13 May-13 Jun-13


Jul-13
Aug-13 Sep-13
Oct-13 Nov-13 Dec-13
13
R Y G R Y G R Y G R Y G R Y G R Y G R Y G R Y G R Y G R Y G R Y G R Y G
Jan-13

Feb-13

KPI
Controlle
0 0 1 1 0 0 0 0 1 0 0 1 1 0 0 0 0 1 1
d
SIA Monthly Review PPT

0 0

0 0 1 0

0 1

0 0 1 1

0 0 0 0 1

Control KPI 1 Pareto & Root Cause analysis with implementation detail
DEFECT REPEATATION

12
10
10

QUANTITY
4

Handle Loose

Metal Insert
removing

Hinge Inclined

SIA Monthly Review PPT

DAMAGE

BOLT LOOSE

PAINT PROBLEM

Item
Sno.
Code

Item Name

IA22025 PANEL SHIELD


9
SIDE UPPER RH

IA22453
5

ASSY. ENGINE
COVER

Nature of Defects
DAMAGE
BOLT LOOSE

JAN'13
FEB'13
MAR'13
APR 13
MAY'13
JUN'13
JUL'13
AUG'13
SEP'13
OCT'13
NOV'13
Dec;13

Customer End Rejection Monitoring from JAN '13-DEC 13

Root Cause
NA

Pin dia was less in


mold.

Action Plan
NA
Mold scraped which was
found wrong

Statu
Target s
Date (RY
G)
NA
02-Mar13

100% of visual inspection


01-Marwill be done of the bolt
13
before dispatch & yellow
sticker is pasted on the hinge
if bolt found wrong

HANDLE

IA22538 PAD SPRAY


1
SUPPRESSION

CD DIMENSION
NOT OK

Drilling fixture verified New drilling fixture made


15-Feb& found not ok
with hardened bush.
12
Checking of gauges is done in
every 4 month.
7

DAMAGE(AIR
IA22360
BATTERY COVER BUBBLE AROUND
9
BUSH

I1)mproper tightening 1)Sop prepared for


01-Novof the screw
tightening the screw
13
Control; plan has also been
revised.
2) Checking of handle by
pulling it is also implemented
at the time of PDI

Drilling process is not Punching will be used for the 8/06/13


adequate .
control of dimension
Painting process has been
Air bubble at the time
25
revised , checking being done
of molding
may13
at primer stage.

G
G

Sno Item
. Code

Item Name

Nature of Defects

DAMAGE

IA30745
2

AIR CLEANER
COVER ASSY

DAMAGE AT
GROMMET

JAN'13
FEB'13
MAR'13
APR 13
MAY'13
JUN'13
JUL'13
AUG'13
SEP'13
OCT'13
NOV'13
Dec;13

Customer End Rejection Monitoring from JAN '13-DEC 13

G
2

C.C OUT
1
IA23018
6
7

COWL GRILL
CENTER (HCV
FACE COWL)

C.C OUT

IA22999
COWL GARNISH
0

Action Plan

DAMAGE

Root Cause

Statu
Target s
Date (RY
G)

LOGO FITMENT
ISSUE

Grommet will be
Crack found at the position of
assemble in parts at
G
grommet
supplier end
Previously grommet was fixed At the time of fixing the
grommet , the adhesive
by hand , due to
10/08/20
is also pasted to give
transportation there are
13
good bonding.
chances of releasing grommet
from parts.
G
Handling damage at VECV
-NIL
G
Different parts were checked It is to be discussed with
dimensionally with logo
the VECV concern
fitment and found ok at
person that part
Sep13 G
VECV by our quality person. provided is ok but the
mating part could not
meet the dimension.
It is analyzed that C.C 280 is
observed 277-278mm.While
mounting the logo taking hole
as reference the last pin (215
C.C in part)is coming out of
the part when logo is fitted.
Logo pin also has variation of
1 mm in C.C dimension.
The 2 mm variation in part &
1 mm variation in logo
resulted in problem
Observed that horse logo
present at VECV is not fitted
and logo at our end has no
fitment issue.

Part, tool & mating part


dimensions measured for
rectifying the tool. Tool
sent to tool maker for
modification in c.d of pin
0/10/201
location.
3
G
Parts provided by filing
the slots as an immediate
action.
New mould pin already
implimented and logo
available at VECV is
brought at our end,parts
19-Jul
now send with checking
logo mounting on the
part at PDI.

Sno.

10

Item Code

Item Name

IA22385

DASHBOARD

IA222215

PANEL SHIELD
T/M LOWER

IC322032

Nature of Defects

PAINT PROBLEM

DAMAGE

Cover Plate Assy. Metal insert removing

ENGINE HOOD
ASSY
11 IA302841

Hinge Inclined
TOTAL

JAN'13
FEB'13
MAR'13
APR 13
MAY'13
JUN'13
JUL'13
AUG'13
SEP'13
OCT'13
NOV'13
Dec;13

Customer End Rejection Monitoring from JAN '13-DEC 13

Root Cause

21 out of 24
Dashboards were
found with polythene
impression on it,.
Also there is
problem with the
paint application
which impart thick
layers on the part
which gives
polythene impression
even after proper
curing time.

10

Handling damage at
VECV.

Action
Plan

Holes in the
polythene is done
after proper curing
time, also electric
17/07/201
heaters provide
3
better curing of part
as compared with
the earlier used gas
furnace oven.

...

the adhesive which We are planning to


we are using is not change our process
compatible to adhere of joining of metal
the metal insert with insert with ABS
ABS .

CD Dimasion of the
hole was found
shifted due to which ,
The hinge found Checking gauge
tilted with respect to provided at PDI to
1
cd dimension
check the hole CD.
1 14 2 1 8 0 13 4 1 1 5 1

Status
Target
(RYG
Date
)

NIL

8/12/13
G

Immediat
e
G

S.No.

WATCHED KPI

MEASURE

WATCH
KPI TREND
FEB MAR APR MAY JUN

JAN

JUL

AUG

SEP

OCT NOV

DEC

54275 27955

61144

-MENT

In-house monthly PDI


PPM

TOTAL Qty

64687

52930

66373

76000

80401

75486

74546

59406

37720

REJECTED

242

200

250

253

323

195

390

286

205

208

98

169

ACTUAL
TARGET
ACTUAL

3741
3800

3778
3800

3767
3800

3470
2500

4020
2500
-*

2580
2500
2680

5231
2000

4814
2000

5434
2000

8678

3520
1500
2000

2760
1500

3338

3680
1500
2800

3500

3500

3200

3200

5000

3000

3000

3000

8931

4950

4800

4850

5000

5000

5000

5000

11139

8051

9580

6850

TBF

7000

7000

7000

7000

2-A

In-house monthly
Process PPM (Molding)

In-house monthly
Process PPM (Filing)

ACTUAL

2-B

In-house monthly
Process PPM
(Painting)

ACTUAL

In-coming monthly
PPM

ACTUAL

2-C

No of DOL parts
4

(Total 68 parts)

PDI Execution (% of
PDI followed
invoices/Total invoices
raised)

TARGET

Activity started from september

TARGET

TBF

Activity started from september


TARGET
3400
4000

0
4000

0
4000

0
3500

0
3500

61

61

58

60

62

62

62

62

63

No OF PDI

60

55

50

ACTUAL

100

100

TARGET

100

100

TARGET
ACTUAL
TARGET

Process audit (No of


parts )

ACTUAL

Dock audit (No of


parts)

ACTUAL

SIA Monthly Review PPT

Activity started from may

TARGET

TARGET

0
3500

0
3000

0
3000

0
3000

0
2500

0
2500

0
2500

63

63

65

65

65

66

66

66

55

51

50

51

60

60

55

55

55

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

Activity started from may

Activity will start from june

30

10

10

10

10

10

10

30

10

10

10

10

10

10

S.No.

MEASURE
-MENT

WATCHED KPI

Raw material
inspection plan

TARGET
ACTUAL

Layout inspection
(No. of parts)
TARGET
ACTUAL

10

FEB

12

Poka Yoke

13

QS Sign off

14

System audit score

MAY

JUN

JUL

AUG

NOV

DEC

10

10

11

..

..

..

Activity started from may..


1
1

ACTUAL
TARGET
ACTUAL
TARGET
ACTUAL

OCT

TARGET
ACTUAL
TARGET

SEP

..

11

APR

..

IMTE and Gauge


Calibration
Tooling validation
(Dies, Jigs & Fixture
validation &
Maintenance)

MAR

Activity started from


APRIL..

ACTUAL

(Third party)

JAN

1
1

1
1

1
1

..

..

..

0
2

1
2

0
2

2
2

2
2

1
2

0
2

2
2
0
40
85%

Activity will start from june..

26

95%

TARGET

KPI Summary
Months

KPI

Jan-13

Feb-13 March-13

Apr-13
R

May-13
R

Jun-13
R

Jul-13
R

Watched 0 0 1 1 0 0 0 0 1 0 0 1 1 0 0 0 0 1 1
SIA Monthly Review PPT

Aug-13

Sep-13

Oct-13

0 0

0 1

Nov-13
R

Dec-13
R

S.
No.

KPI

controlled

Watched

Open Red KPI Status


Month

SIA Monthly Review PPT

Red
Parameter

Reason

Root Cause

Action

Target
Date

Resp.

Status

Inhouse
Rejection

Hole Not Clear

During painting
metafill deposition
mistakenly on the
part lead to hole
block.

Painting supervisor
instructed to check part
visually before sending
to PDI. & Clear hole
before proceeding

Immediate

Mayur
Ajmera

Road-map status to achieve KPI


KPI

Action to achieve the KPI

In-house monthly PDI PPM

In process improvement & in process


checking
Supplier up gradation through
supplier audit

In-coming monthly PPM

No of DOL parts

Process audit
Raw material inspection plan

100% gauging implementation, And


special focus on repeated issue
Defect analysis in QRQC

System audit score


SIA Monthly Review PPT

RESPONSIBILITY

June'13

Mr.Mayur Ajmera

July'13

Mr.R.Patidar
Mr.Mayur
Ajmera,Mr.Laxman
Surage and
Mr.Mayaram Sharma
Mr. Jasvin S Bhatia

July'13
Jan'13

Information of defect to the down


level through involvement of
workers in QRQC

Jan'13

Strengthening the QC department

June'13

Top Management

Third party involvement for


inspection

July'13

Mr.Mayur Ajmera

April'13

Mr. Rajan S Patta

Daily QRQC & Involvement of CFT


team

Jan13

Mr. Mayur Ajmera

Internal Audit

June'13 &July'13

QC & MR

Tooling validation (Dies, Jigs & Validation of drilling fixtures with in


Fixture validation & Maintenance)
4 months
Poka Yoke

TARGET

Top Management

Layout Status
S.
Month
No.

Comp.
Planed

1 Jan-13
2 Feb-13
3 Mar-13
4 Apr-13

7
7
5
5

Comp. N. C.
Cumulati
N. C.
Complet obser
ve Open
Closed
ed
ved
N.C.
0
1
0
1

7
7
5
5

Reason for open NC

Target
date for
Open N
C

5 May-13

10

10

Drawing req. from VECV.

15 JULY
2013

Jun-13

As per fitment part is ok, but still it is to


verify whether dim variation.

15 JULY
2013

7
8
9

Jul-13
Aug-13
Sep-13

6
9
6

6
9
6

0
1
1

1
1

0
0
0

10 Oct-13

11 Nov-13
12 Dec-13

9
4

9
4

0
0

12
10
8
6
4
2
0

10
8
6

55

9
7

66

8
6

No. of Parts completed

SIA Monthly Review PPT

100% Green Parts

Resp.

Remarks

vecv

Horizontal slots
converted to vertical as
per req in air cleaner
cover assy.

Quality
dept.

Due to fouling of RH part in mudguard 12


mm trimming of the part has to be done
VECV Mr. The drawing has to be
according to the fitment purpose, But the 15/10/1
Vinay
revised according to the
LH (IA222296) IS SUPPLIED
3
Gupta
reduced width
ACCORDING TO THE WIDTH GIVEN IN
DRAWING .

99

2.5
2
1.5
1
0.5
0

2
11
000

11
0

000

Total N.C.

11

11
0

N.C. Closed

11
000

11

1
00

000

Cumm. Pending N.C.

In-house PPM Trend


PARETO FOR TOP CONTRIBUTOR

INHOUSE PPM TREND


6000
5000
4000
3000
PPM

2000
1000

40
35
30
25
20
15
10
5
0

TOP CONTRIBUTOR OF DEC'13

34
26

24

21
5

REJECTED
QUANTITY

In-house Rejection Status


S. No.

Part No.

ID206599

SIA Monthly Review PPT

IA303087

IA218893

NonRepeated or
conformance
Root Cause
Not
Detail
Hole Not
Clear
R
e
p
a
t
e
Hole Not Clear
d
Hole Not
Clear

During
painting
metafill
deposition
mistakenly
on the part
lead to hole
block.

ACTION

Target date

Painting
supervisor
instructed to
check part
visually
Immediate
before
sending to
PDI. & Clear
hole before
proceeding

Resp.

Status

Mayur
Ajmera

Improvement plan & status


Sl. No

Particulars

IMPROVEMENT PLAN 2013


PLAN DETAILS
Target

Responsibility
Mr. Mayur Ajmera

Raw Material Inspection


Third party
APRIL '13
Measurement of Raw
Material at shop floor
MAY'13

Avoid repeated customer


complaint

Mr.Mayur Ajmera

4
5

6
7
8
9

Quality related improvements

Dock audit to be conduct

JUNE'13

Arrange of all gauges near


the working area.
JULY'13
100% Guaging
Implementation of all the
parts

Aim for 0 ppm at


customer end
100% will be checked in
layout report.
To achieve quality System
Audit Score 95%

10

Punching Die
Implementation For all
types of mud flap

11

Machine for Dry


Sandering Is to Be Started
For Better Results

SIA Monthly Review PPT

JUNE'13

Mr. Abhinav

Mr. Jasvin S Bhatia


Mr.Jasvin S Bhatia

Mr.Mayur Ajmera; Mr. Laxman Surage


JULY'14
JULY'13
JULY'13
AUG'13

Mr. Mayur Ajmera


Mr.Jasvin S Bhatia
Mr. Mayur Ajmera

Mr. Nikhil Jain


AUG'13
Mr. Mayur Ajmera
SEP'13

POKA YOKE IMPLEMENTATION DEC13


CHECKING GAUGE FOR CD DIMENSION ENGINE HOOD ASSY IA302841

CD dimension

Checking of Hole By qualifying with PIN

SIA Monthly Review PPT

General Awareness About 5S

Training conducted at our plant regarding general awareness


about 5 S, under the guidance of Mr. Sanjay Agrawal Sir.

SIA Monthly Review PPT

Thanks

SIA Monthly Review PPT

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