QC CIRCLE PRESENTATION

BY
CHENNAI TIGERS
RNAIPL
BODY LINE #
1

QC CIRCLE TEAM BODYSHOP

SUDEESH
Leader

RAJAGOPAL
Facilitator

VASU
Sub Leader

RAMUKUMAR
Team member

P
KARUPAN
Team
member

KARTHIK
Team member

MUTH
U

Team member

OBJECTIVE: To Improve SUBFLOOR Straight thru ratio(STR)

@
TCF BY REAR ABS COVER STUD FAILURE ELIMINATION

BODY SHOP: SUBFLOOR

To Improve Body Shop Straight thru ratio @

TCF
QC CIRCLE THEME

<Shop >
Body # 1

<QC Circle Theme

>

ELIMINATION OF REAR ABS

COVER M6 STUD FAILURE IN
H79 MODEL

<QC Circle Name>

CHENNAI TIGERS

THEME SELECTION :
QC THEME SELECTION BASED SUBFLOOR AOP KPI
FSTR TARGET ( April15 ~ MARCH 16 )c

SUBFLOOR AOP CONTROL ITEM

MONTIORING SHEET

AOP KPIS are unachieved:

DELIVERY(STR), QUALITY

1.F STR AT TCF TARGET NOT ACHIEVED FOR JAN15

TO APRIL 15 (DELIVERY KPI)
2. V1 QUALITY DEFECT OUTFLOW(QUALITY KPI )

THEME SELECTION REASON :

SUBFLOOR ZONE STR AT TCF FY15

100

100

STR

SUBFLOOR STR TREND FOR H79 R/N

100

TARGET %

100

100

90
80
70
60
50

94

98

97

96

40
30

1.

20
10
0

2.
3.

F STR TARGET NON

ACHIEVEMENT FOR
H79(DELIVERY)
HIGH REPAIR TIME
(COST)
EFFECT ON
CUSTOMER(QUALIT
Y)

TARGET -100%

ACTIVITY SCHEDULE

CURRENT STATUS: DATA COLLECTION AND ANALYSIS

H79R/N STR STUD FAILUR OFFLINE TREND AT TCF FOR 6 MONTHS

100.0

100.0

95.5
90.0

89.8

100

80.0

REAR ABS COVER STUD

FAILURE IN H79 MODEL

80

75.0
70.0

60.0

59.1
60

50.0

40.0

38.6
40
34

30.0

Axno of cocern

20

20.0

18
14

13
10.0
5

4
0.0

percentage

QC STORY - CURRENT STATUS GRASPING

STR Outflow -ABS COVER STUD FAILURE (H79)

9
8

77

6
NO OF CARS

QC ACTIVITY
START

G
O
O
D

3
2
1
0

DEC'14

JAN'15

FEB'15

MAR 15
Month

MONTH WISE STR OFFLINE TREND DATA

FOR ABS COVER STUD FAILURE

APRIL'15

MAY'15

JUNE 15

QC CIRCLE THEME

<Shop >
Body # 1

<QC Circle Theme

>

ELIMINATION OF REAR ABS

COVER M6 STUD FAILURE IN
H79 MODEL

<QC Circle Name>

CHENNAI TIGERS

QC STORY - TARGET SETTING

CHALLENGE 100%
ELIMINATION OF REAR ABS
COVER STUD FAILURE IN
H79 MODEL

OFFLINE STR IN TCF

8
6
DPU

2
0

april'15

MAY'15

Month

JUNE 15'

JULY 15'

TARGET SETTING : TO ELIMINATE REAR ABS COVER STUD

FAILURE IN H79 MODEL

PICTORIAL DETAILS OF REAR ABS

COVER STUD LOCATION

REAR ABS COVER FIXING

POINT

Grade defination
Judgement grade
Defination

V1

Concerns
VES definition of body
where all
customer
dissatisfied
& claim for
repair

V2

V3

Most of
customers
point out in
questionnair
e in survey

Some
customers
aware of
quality but
most of them
accept

REAR ABS COVER STUD POSITION

1.REAR ABS COVER FIXING STUD FAILURE
AFFECTS CUSTOMER SAFETY

BRAIN STORMING SESSION

BRAIN STORMING

CIRCLE MEMBERS
VOTING
1.RAMKUMAR
2.KARTHICK
3.MUTHU
4.PKARUP
5.VASU

6. Factor Analysis
1

H79 REAR ABS COVER M6 STUD WELD

FAILURE

MAN

MACHINE

METHOD

Stud welding angle not

maintained
Weld
cycle not
complete
High speed
stud gun
handling

Stud Gabari panel gap and Bush loosening

Stud Gun Angularity

setting concern
New operator
doing
the process

Manual clamp improper locking

Stud collet
carbon deposit

Trim Matching part not alig

OTHERS

Clamping shaking and Bend

Stud Gun
parameter

Stud strength
confirmation not
done

RR ABS Cover
M6 Stud Failure
Oil Contamination)

Low Awareness
Stud weld
Process
parameter and
equipment
concerns

During the rework of stud

Gabari not used

Supplier part matching

Thickness high,flatness
uneven in RR MBR
LOWER ASSY CROSS

High thickness of sheet metal(5mm)

MATERIALS

3.2 FACTOR ANALYSIS MAIN FACTOR ANALYSIS

Sl No

4M

Main Factors

Points for verification

MAN

SKILL LEVEL

STUD WELD GUN HANDLING SKILL

MAN

KNOWLEDGE

MACHINE

STUD WELD EQUIPMENT PARAMETER

STUD WELD INTEGRITY ,DEFECTS

AWARNESS
PARAMETER , WELD GUN
ANGULARITY,FEED BACK SIGNAL

MACHINE

COLLET,FLASH SHEILD ,EARTHING FOR

STUD WELD EQUIPMENT

COLLET LIFE, FLASH SHEILD LIFE,

EARTHING BLOCK CONTACTS

METHODS

RIGID SEATING, GAPS, FLATNESS IN PANEL

PROFILE

RIGID SEATING, GAP BETWEEN FLASH

SHEILD AND PANEL

METHODS

STUD GABARI

STUD GABARI DESIGN, WORKING

ACCESSBLITY, SEATING,

MATERIAL

OIL CONTAMINATION, THICKNESS, PROFILE

FLATNESS,

OIL CONTAMINATION, MATERIAL

GRADE(SPC, GA), THICKNESS

WHY WHY- ANALYSIS

MAN

WHY

WHY

WHY

1. STUD WELD
CYCLE NOT
COMPLETE

GUN ANGLE
NOT
MAINTAIN

OPERATOR NOT
AWARE OF
PERPENDICULARI
TY

STUD GUN
USAGE IN
ANGULARTIY
SWITCH
DEACTIVATED
MODE

2. STUD WELD
CYCLE NOT
COMPLETE

DEFECTIVE
DROP DOWN
TIME

STUD GUN
ROUTING
IMPROPER

STUD GUN HOSE

ROUTING NOT
PROPER With
Spring Balancer

3. STUD WELD
CYCLE NOT
COMPLETE

LIFTING OF
GUN BEFORE
PROCESS
COMPLETION

LACK OF
AWARENESS ON
STUD WELD
INTGERITY

HIGH SPEED
STUD GUN
HANDLING

WHY

VERIFICA
TION
RESULT

SOLUTIO
N

OK AS PER
STANDARD

-STUD GUN
ELONGATION
ON OPPOSITE
Direction

OK AS PER
STANDARD

NG- RESULT
FOUND NG

AWARENESS
TRAINING ON
STUD WELD
INTEGERITY
AND STUD
WELD GUN
HANDLING

3.3 FACTOR VERIFICATION :

1. MAN SKILL LEVEL: STUD WELD GUN HANDLING /

Significant
Key factor: High speed weld Gun handling
leads to weld cycle incomplete

Not significant

WHY WHY- ANALYSIS

MACHINE

WHY

WHY

1. STUD GUN
COLLET AND
FLASH
SHEILD
WORN OUT

HIGH
CARBON
SPATTER
DEPOSIT
ON THE
COLLET
AND FLASH
SHEILD

COLLET/FLASH
SHEILD
CLEAING DONE
2 TIMES PER
SHIFT

NG: STUD
FAILURE
OBSERVED

REVISION
FOR STUD
COLLET
/FLASH
SHEILD
CLEANING
FREQUENCY
(1HRLY
ONCE)

2. STUD
WELD GU N
PARAMETER

STUD WELD
GUN
CURRENT
PARAMETER
VARIATION

DROP OF
CURRENT
DURING STUD
WELD PROCESS

OK AS PER
STANDARD

NO Current
variation
observed

STUD WELD
GUN
ANGULARIT
Y
BYPASSED

FEED BACK
SIGNAL NOT
PROPER
RESULTING IN
ERROR GREEN
LIGHT NOT
GLOW

NG: FLAT
NESS FOUND
UNEVEN

TO BE FOR
UNEVEN
FLAT NESS
IN PART
DESIGN
LEVEL

3. STUD GUN
90 DEGREE
ANGULARITY
SETTING ISSUE

EARTHING

WHY

STUD GUN
BASE PANEL
PROFILE
UNEVEN IN
FLAT NESS,

WHY

PROFILE
FLATNESS
VARIATION

VERIFICA
TION
RESULT

SOLUTIO
N

FACTOR VERIFICATION :

2. Machine: Stud WELD GUN 90 Degree Angularity

1.Stud Gun 90 Degree Set and BY Pass Trail
weld Done
2. Stud Gun flash sheild and Collet Worn out
Trail

Stud Failure observed, Strength Low

Significant

Trial part

Not
significant

WHY WHY- ANALYSIS

METHOD

WHY

WHY

1. STUD
GABARI TO
BASE PANEL
GAP

HIGH
THICKNESS
OF STUD
GABARI

STUD GABARI
FRP MATERIAL
THICKNESS
HIGH

2.STUD
GABARI TO
BASE PANEL
GAP

MANUAL
CLAMPS
IMPROPER
LOCKING

MANUAL CLAMP
WORN OUT

WHY

CURVE
PROFILE
GABARI NOT
SEAT WITH
PANEL:HIGH
GAP

WHY

VERIFICA
TION
RESULT
OK AS PER
SOP

NG: EXCESS
GAP FOUND
AFTER
CLAMPING

SOLUTION

STUD
GABARI
DESIGN
NEED TO
CHANGE MS
STEEL.
MODIFICATI
ON TO BE
DONE
PNEUMATIC
CLAMPS TO
BEIMPLEME
NTED

FACTOR VERIFICATION :

3. Method: Gap Between Stud Gabari and Panel

Significant
Gabari Improper locking manual clamp play
creating Gap , More force need to exert on
Gun .Stud failed during strength check

Not significant

WHY WHY- ANALYSIS

MATERIAL

WHY

WHY

1.
MATERIAL
:OIL
CONTAMINATI
ON(REAR
FLOOR REAR
MBR CROSS)

OIL
CONTAMINA
TIO IN
RECEVING
LEVEL

ANTI RUST OIL

FOUND IN
MATERIAL

2. PANEL
PROFILE FLAT
NESS
/CONCERN IN
REAR FLOOR
REAR MBR
CROSS

PANEL
PROFILE
FOUND
FLAT NESS
FOUND
VARIATION

SPOT
UNDULATION
INCOMING PART

WHY

WHY

VERIFICA
TION
RESULT

SOLUTIO
N

OK AS PER
STANDARD(
NO excess
oil)

SPOT
LOCATION
SHIFT FROM
IN PART

2 SPOTS
LOCATED IN
STUD WELD
LOCATION .

NG:PROFILE
FLATNESS
UNEVEN DUE
TO SPOT
UNDULATION.
1. STUD
FAILURE
OBSERVED
ON STUD
WELDED
ABOVE THE
SPOT
2. STUD WELD
GUN
ANGULARIT
Y SETTING
CONCERN

MATERIAL
DESIGN TO
BE CHECKED
AND SPOT
LOCATION
CHANGES TO
BE DONE AS
PER DESIGN

FACTOR VERIFICATION :

4. Material : Rear Side Mbr lower Assy part profile flatness

Significant
1. Profile Found uneven, Due to Spot
mislocation and Uneven Interference

Not significant

FACTOR VERIFICATION :

3. Material: OIL Contamination in panel

Significant
Excess oil leads to stud failure.No Excessoil
found in part

Not significant

DETERMINATION OF COUNTER MEASURES

S.NO

ASSUMED MAIN
FACTORS

1
Man :Working
skill

M
A
I
N

CAUSES

IMPROVEMENT ACTIONS PROPOSED

FESABIL
ITY
CHECKI
NG

a)High speed
stud gun handing
leading to weld
cycle incomplete

1. Lack of awareness
on stud weld
integrity .
2. Lack of awareness
on high speed
working impacts on
stud welding

1. Basic Stud weld training

with practical
awareness' training
planned .
2.
Focus on stud weld
failure modes doing
negative validation of the
above factors

YES

Machine :Stud
Gun Angularity

a.Stud Gun
angularity 90
degree setting
Concern

1.Stud Gun angularity

setting concern due to
base panel profile
uneven and excess gap
due to stud weld
gabari and Base Rear
floor Assembly

1.Stud Gun angularity

affecting concerns to
focused on main factors
contributing .EX(Panel to
stud gap,Gabari design to
be changed
2. Base profile uneven
factors contributions to
checked

YES

Method :Manual
clamp Concerns
and Stud Gabari
Bush Loosening
and play

a. Manual Clamps
application
and Stud
Gabari Bush
Design
concerns

1. Stud fixture Manual

clamps not fully
locked and clamped
leading to Gaps.
2. Stud Gabari bush
loosening concerns due
to poor gabari design

1. Pneumatic Clamps to be
implemented for improving
rigidity in stud Gabari
clamping .
2.Stud Gabari Abs cover
design to changed from FRP
to Cast iron to improve

YES

F
A
C
T
O
R
V
E
R
I
F
I
C
A
T
I
O

ANALYSIS AND
VERIFICATION ITEMS

DETERMINATION OF COUNTER MEASURES

S.NO

M
A
I
N

ANALYSIS AND
VERIFICATION ITEMS

CAUSES

IMPROVEMENT ACTIONS
PROPOSED

FESABILITY
CHECKING

Method
:Manual
clamp
Concerns in
stud fixture

a. Manual Clamps
application
Concernns

1. Manual clamps join

wear out leading to
clamp uneven locking.
2. Improper locking and
unlocking leads to
Clamp hit damage
during unloading the
assembly

1. Implementation of
Pneumatic clamps to
improve for
improving the
holding of clamps.
2. Improves in one
switch even locking
and unlocking of
clamps s

YES

Machine
:Stud weld
collet
concerns

a.Stud weld Collet

worn out and
arching issues

1.Carbon Deposit and

weld spatter
accumulation on the
stud Collet leading to
wear of stud collet
surface and weakening
of stud holding force
and frequent arching
and poor welds

1.Stud weld Collet

cleaning frequency
Day wise schedule
implementation and
monitoring with
Effective TPM
implementation

YES

Material: RR
Side mbr
Lower Assy
Cross part
LH/RH

a. Material base
profile uneven
for stud head
positioning

1. Material base profile

uneven due to Spot
interference in stud
weld location due to
spot miss location in
part level

1. Material (RR Side

MbR Assy Lower
cross part ) stud
surface to be made
even by avoiding the
spot interference in
stud location.
2. Interefering Spot

YES

F
A
C
T
O
R
V
E
R
I
F
I
C
A
T
I
O
N

ASSUMED MAIN
FACTORS

Stud Welding
Fixture

COUNTER MEASURE IMPLEMENTATION

Before Condition

After Condition
Manual Clamping
Operation in Stud
Fixutre

1. Manual clamp Improper locking

Leads to Panel Gap creates
ABNORMALITY During stud Gun
Angularity teaching and Setting

1. Pneumatic clamps Good

Clamping Pressure
2. Rigid and Improved Clamping
3. GAP b/w Panel and stud Gabari
Reduced

Stud Welding
Fixture

COUNTER MEASURE IMPLEMENTATION

Before Condition

After Condition

FRP TO CAST
IRON

1. Stud Weld Gabari made of FRP

Material
2. High Thickness
3. Stud welding locating Bushes
fixed in FRP Material
4. Frequent Stud Gabari Bush
loosening and Comes out issue
5. Leads to Stud Gun Angularity
teaching and Setting.
6. Cause for Stud poor weld and

1. Cast Iron Material Selected to

Frame Stud Gabari For LH/RH ABS
Cover Studs.
2. Rigid in Design and Stud Gabari
Bushes Firmly welded in new
Gabari.
3. Stud bush Comes out and play
issue Resolved

COUNTER MEASURE IMPLEMENTATION

TRAINING AND AWARENESS
SESSIONS

FAILURE MODE
ANALSYIS

Training and awareness sessions on

Stud Weld process parameters and
Integrity

:TEAM
HIGH SPEED STUD GUN HANDING
IMPACTS

KEY LEARNINGS

COUNTER MEASURE IMPLEMENTATION

TRAINING AND AWARENESS
SESSIONS

Training and awareness sessions on

Stud Weld process parameters and
Integrity

FAILURE MODE :TEAM ANALSYIS BY

NEGATIVE VALIDATION
Brain storming and knowldege
sharing

KEY LEARNING

17.04.15

COUNTER MEASURE IMPLEMENTATION

H79 Rear Abs Cover fitment

MBR ASSY-SIDE RR CRO(76454 3761R)

MATERIAL SPOT INTERFERNCE IN STUD LOCATION

Causes
1.Supplier spot shifted and welded in stud weld location creating poor weld current penetration
during stud welding.
2.Spot location variation found part to part.
3.Stud Getting failure during mallet check leading to process delay.
4. Stud weld Gun angularity setting not able to maintain due to uneven profile due to spot impression.
5.Day wise 6 cars get failure during stud strength check .

Temp action:100% mallet check in process and quality gate to prevent out flow
Perm action :Supplier spot need to shift 20mm from current position (PQA Team/Body PE)

Stud Welding
Fixture

COUNTER MEASURE IMPLEMENTATION

Before Condition

After Condition
4M CHANGE
IMPLEMENTATION
IN MATERIAL

1. MATERIAL SPOT
INTERFERNCE IN STUD
LOCATION
2. FREQUENT STUD FAILURE
ON THIS LOCATION

1. MATERIAL 4M CHANGE
IMPLEMENTATION IN SPOT
SHIFTING DONE IN
INCOMING PART .
2. ACTION IMPLEMENTED AT
SUPPLIER END BY DESIGN
TEAM

Stud Welding
Fixture

COUNTER MEASURE IMPLEMENTATION

Before Condition

After Condition

4M CHANGE
IMPLEMENTATION
IN MATERIAL

1. REAR ABS COVER M6 STUD

WELDED ON TOP THE
SPOT WELD.
2. POOR STUD WELD FUSION
DURING STUD WELDING
3. FREQUENT FAILURE

1. REAR ABS COVER M6 STUD

WELDED IN LOCATION AS
PER 4M CHANGE
2. STUD WELD QUALITY
IMPROVED
3. NO STUD FAILURE
4. NO SPOT INTERFERENCE IN
STUD LOCATION

RESULT CHECK

CHECK THE RESULT- MONITORING

STR Outflow -ABS COVER STUD FAILURE (H79)

9
8

77

6
NO OF CARS

QC ACTIVITY
RESULT

G
O
O
D

3
2
1
0

JAN'15

FEB'15

MAR 15

APRIL'15

MAY'15
Month

REAR ABS COVER STUD FAILURE AT

TCF:RESULT CHECK

JUNE 15

Jul-15

Aug-15

Sep-15

Standardization & Root Cause Control

Training to all On Stud weld Tpm KEY

FOCUS ON STUD GUN AND COLLET DAILY
TPM
This is Tpm
Poin t !!!

Daily Check & confirm by Team

members to prevent collet damages
and arching


7.0 Standardization and control method

Item

Standard ization

Education
Horizontal
deployment

Spot shifted to
15mm
Change in
supplier part

To eliminate the spot

weld interference in
stud location

SUDEESH/RA
JENDRAN

JUNE15

SUBFLOOR

SPOT Shift in
LOWER ASSY REAR
CROSS PART AT
GSSA supplier

TPM check
point .

STUD WELD GUN

COLLET
CONFIRMATION

SUDEESH

JUNE 15

SUBFLOOR

TPM CHECK SHEET

STUD Weld
Operation
standards

TO Avoid stud failure

duringprocess

RAJAGOPAL

MAY15

SUBFLOOR

One point lesson

standards

Operator
training and
Awarness

To improve knowledge
on stud weld failure
modes

SUDEESH/RA
JAGOPAL

MAY 15

SUBFLOOR

Practical genba
Training on stud
weld failure modes
with Tear down
confirmation

FRONT
FLOOR

To Prevent stud weld

Failure

SUDEESH

JUNE15

SUBFLOOR

One point lesson

standards

Reflection of the Activity (Learning)

SUDEESH- Individual capabilities of Problem Solving ,Kaizen Mind and Team work to FIND
SOLUTIONS

VASU- Importance of Team Work by Brain Storming will result in Effective Countermeasures.
KARTHICK - We Understood the importance of PDCA which is very important for permanent
solution to Problems
RAMUKUMAR- GOOD TEAM ACTIVITY ,MANY IDEAS GENERATE FROM TEAM

PERYIA We Learnt the importance of Cause and Effect Diagram and the usage of QC tools.

MUTHU WE WORKED AS A TEAM TO GET THE RESULT, TOGETHER WE ACHIEVE.

Body shop
Thank you very much for attention