Kaizen Event.pdf

7/28/2019 Kaizen Event.pdf

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KPO/UKE304/Sanjay Kumar

Window winding hard Project @BIW 1C

KAIZEN Event

On

TO ELIMINATE WINDOW WINDING

HARD PROBLEMAt

BIW 1C Shop

Uttarakhand

FROM 25.06.2012 to 29.06.2012


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Objective & Target

OBJECTIVE

(1) Tovalidate all child parts.

(2) To Establish standard work sheet.

(3) To Identify quality check points.

(4) To validate all process stage wise.

TARGET :

To eliminate the door glass movement hard defect from TCF.

To minimize the rework downtime loss in Line for glass hard.

To maintain proper sash gap for smooth movement of glass from BIW end.


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(MENTOR )

SANJEEV KUMAR

SANJAY KUMAR RAKESH JOSHI

(LEADER)VARTIKA BISHT (KPO)

PANKAJ (QUALITY)

(DY. LEADER)

SANDEEP KUMAR (MFQ)

SHASHANK (KPO TRAINEE

SUVIT(KPO TRAINEE)

Kaizen Event Team Members

SUHAS (MQA)


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GEMBA VISIT

REVIEW MEETINGMORNING MEETING

KAIZEN EVENT FLOW

Kaizen Event Opening Ceremony

Guidance by Senior Mgt.


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DATA COLLECTION

DATA COLLECTION


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PROBLEM STATUS

45%

55%

0%

10%

20%

30%

40%

50%

60%

FREQUE

NCY(%

RH DOOR LH DOOR

DEFECTS

PROBLEM STATUS

Series1


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40%

5%

0%

5%

10%

15%

20%

25%

30%

35%

40%

FREQUENC

BEFORE AFTER

WINDOW WINDING HARD

TARGET


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5W 1H ANALYISIS


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CAUSE & EFFECT DIAGRAM


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WHY WHY ANALYSIS


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Bending in Glass guide channel

Bending in Glass guide channel in edges-100%

KAIZEN DONE


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Operation/Machine Problem Measure Taken Results

Earlier C type gun is used

for providing the spot

welding at the edges of the

glass channel which dueto striking with channel

provides the bending at

edges.

Now X type gun is used at the

edges to prevent the bending of

the channel

Now no bending profile

is observed at the edges

After KaizenBefore Kaizen

KAIZEN DONE

Earlier C type gun is used

for providing spot welding

on the edges of Glass guide

channel

Now X type gun is used to

prevent the bending of glass

channel bending at edges

Spot welding machine


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Bkt width uneven

Glass guide channel/bkt Width uneven

WHY WHY ANALYSIS


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WHY WHY ANALYSIS

KAIZEN DONE


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No gauge is present at

supplier end for

measuring the thicknessof glass guide channel

after fitment & before

delivering to TCF.

A gauge is prepared of 17mm

for checking the gap, &

trained the operators atsupplier end for using the

same.

Checked the lot afterimplementing the

gauge, no variation is

found .


KAIZEN DONE

Gauge for

measuring

the glass

channel gap.

To check the glass

guide channel gap

KAIZEN DONE


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Earlier the Mylor used to

clamp the glass guide

channels strike with thechannel & creates

bending profile onto it.

Shim were removed from the

Mylor & adjusted the proper

difference for clamping theglass guide channel.

Now glass guide

channel doesnt bend

during Mylor clamping


KAIZEN DONE

KAIZEN DONE


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Earlier after receiving

parts glass guide

channel) supplier usedto store that part in

carton box, thus its

profile varies in

transferring & placing

the loosely in ground

during fitment.

Arranged a trolley & keeping in

view the profile of channel

special rods were welded, asshown. Now the channels are

placed in this trolley & carried

from store to workplace..

No deformation is

observed during

fitment now, & partswere properly stored &

fitted in line.


KAIZEN DONE

Trolley is made for

placing the loose glas

guide channels to

avoid deformation

Loosely placed glass

guide channels

Storage area of glass

guide channel


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Difference in Sash Gap

Difference in sash gap

Uneven gap 14.3-16 mm

WHY WHY ANALYSIS


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KAIZEN DONE


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No gun guide is present

thereby glass guide

channel during clamping

slips away from its

location & creates sash

gap.

Prepared a gauge for holding

the Glass guide channel &

GRM bkt to avoid

mismatching.

Now the glass channel

& GRM bkt are properly

matched for smoothrunning of glass


Gun guide is

provided for rigid

support to glass

channel

Glass Guide channelassembly fixture

Gun

guide

provided


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BRACKET SHIFTING

Glass movement is

restricted due to misalignmentand mismatching of the sash

profile and channel profile.

Both profiles should match

each other to obtain smooth

motion

Bkt Shifting, leading to mismatch

of glass guide channel with Bkt

KAIZEN DONE


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No gauge is present for

matching the glass guide

channel with GRM bkt,

thus mismatching of

both occurs while glass

movement.

Prepared a gauge for holding

the Glass guide channel &

GRM bkt to avoid

mismatching.

Now the glass channel

& GRM bkt are properly

matched for smoothrunning of glass

After KaizenBefore Kaizen Gauge is made formatching the GRM bkt

& Glass guide channel

in TCF

Rod is provided

with gauge to

prevent the motion

of Bkt & Glass

guide channel

Matching of glassguide channel

No gauge

was present,

earlier


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EXCESS BURR

SASH & GLASS GUIDE

CHANNEL POSITION

MISMATCH

BURR

Burrs in the channel

and sash result intoreduction of effective

GRM gap

KAIZEN DONE


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Spot welding m/c

electrodes tip were

found to beweared,thereby spots

created were of

abnormal size.

We have changed the

electrodes tip of all the Spot

welders & made a schedulechecklist for daily checking

the electrode before starting

the m/c.

Spots are now of

proper dimension &

are not generating thedents as seen earlier.


Electrode tips are

changed

Filing is done beforestarting the m/c

according to provided

scheduleWeird electrode

providing oversize

spots after welding

Spot Welding m/c

KAIZEN DONE


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Earlier no gauge is

available in BIW for

checking the sash gap &

channel gap thusvariation in gap is

received at TCF.

Gauge is provided of 17mm

thickness in line & every

vehicle door is checked for

gap variation before sendingto paint shop.

Variation is minimised

in TCF


Fitment of glassguide channel

ONE POINT LESSON SHEET


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ONE POINT LESSON SHEET


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Activities Done In BIW

Trial of window

winding hard done at

BIW end , keeping in

view all the

improvements done in

house & supplier end

KAIZEN NEWSPAPER


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TOTAL KAIZEN IDENTIFIED =14

COMPLETED = 10

INPROCESS=04

RESULT


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45%

5%6%

0%10%

20%

30%

40%

50%

Frequency(%)

Before event Target Achieved

Defects

Result OF RH Door Glass Hard

Before event

Target

Achieved

55%

5%8%

0%

10%

20%

30%

40%

50%

60%

Frequency(%)

Before event Target Achieved

Defects

Result of LH Door Glass Hard

Before event

Target

Achieved

Target Achieved 95%

(To reduce DPV)

Target Achieved 92%

(To reduce DPV)

Documents

Kaizen Event.pdf