CUSTOMER COMPLAINT & PROCESS

REJECTION REDUCTION IN CYLINDER HEAD

BITS ZC423T: Project Work

by

A.Marimuthu

200618TS246

Project Work work carried out at

HYUNDAI MOTOR INDIA LTD, CHENNAI

Submitted in partial fulfilment of B.S. Engineering Technology /

Information Systems degree programme

Under the Supervision of

Name and Designation

Mr.V.Murali., Asst.Manager
HYUNDAI MOTOR INDIA LTD, CHENNAI.

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE

PILANI (RAJASTHAN)

October 2009

1
 CERTIFICATE

This is to certify that the Project Work entitled CUSTOMER COMPLAINT

AND PROCESS REJECTION REDUCTION IN CYLINDER HEAD

and submitted by

A.MARIMUTHU having ID-No. 200618TS246 for the partial fulfilment of

the requirements of B.S. (ENGINEERING TECHNOLOGY) degree of BITS,

embodies the bonafide work done by him/her under my supervision.

____________________

Signature of the Supervisor

Place : CHENNAI

Date:

Name, Designation & Organization & Location

V. MURALI
Asst.manager &
HYUNDAI MOTOR INDIA LTD
Plot no : 1, Sicot Industrial
park,
Sirperumpudur T.K,
Kanchipuram DT,
PIN CODE-602 105

2
 BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI
DISTANCE LEARNING PROGRAMMES DIVISION
First Semester 2009-2010 Fax No. : 01596- 244183

ID No. : 200618TS246
NAME OF THE STUDENT : A.MARIMUTHU
EMAIL ADDRESS : a_mari_muthu@yahoo.co.in
NAME OF THE SUPERVISOR : V. MURALI
PROJECT WORK TITLE : PROCESS REJECTION REDUCTION IN CYLINDER HEAD

Project Work Final Evaluation (Please put a tick (a ) mark in the appropriate box)
S No. Evaluation Component Excellent Good Fair Poor
1. Final Project Work Report
2. Final Seminar and Viva-Voce

S.No. Evaluation Criteria Excellent Good Fair Poor

1 Technical/Professional Competence
2 Work Progress and Achievements
3 Documentation and expression
4 Initiative and Originality
5 Research & Innovation
6 Relevance to the work environment
Please ENCIRCLE the Recommended Final Grade: Excellent / Good / Fair / Poor
Remarks of the Supervisor:
Supervisor Additional Examiner
Name

 
Qualification B.E mechanical B.E mechanical
Designation 
 

Employing Plot No:1, Sipcot Industrial park, Plot No:1, Sipcot Industrial park,
Organization & Sriperumpudur T.K, Kanchipuram DT, Sriperumpudur T.K, Kanchipuram
Location Pin code-602 105 DT, Pin code-602 105
Phone Number

 
 


Mobile Number
Email Address  
Signature
Place & Date CHENNAI & CHENNAI &

3
 ABSTRACT

The Project is concerned with the identification of the major contributor for

the excess

1. Customer Complaint

2. Process Rejection

of Cylinder Head line and to reduce the same. The analysis has been

done based on the data of the past 1 year and various parameters related to the

problem have been analysed and solutions taken.

The identified problem has been Defined, the parameters affecting have

been measured, key parameters have been analysed and then they have been

Improved based on its criticality.

4
 CONTENTS

Page
Chapter Description
No.
1. PREAMBLE
1.1 Introduction 6
1.2 Problem on hand 7
1.3 Importance of the Problem 10
1.4 Scope of the Project 12
2 DETAILS OF THE ORGANISATION
2.1 Introduction 13
2.2 The Organisation 15
2.3 Organisation Business Profile 22
2.4 Other relevant Information 25
2.5 Conclusion 25
3 DEFINE
3.1 Customer Complaint Trend – Cylinder Head Line 27
3.2 Production & Rejection Details 28
3.3 Cost wise rejection Details 29
3.4 Process Rejection Trend – Cylinder Head Line 30
3.5 Layout – Kappa Cylinder Head Line 32
3.6 Process Flow Diagram 33
4 MEASURE
4.1 Process Capability Study 40
5 ANALYSE

5.1 Cause & Effect Diagram 42

5.2 4M Analysis 43

6 IMPROVE
6.1 Action taken for Major Causes 46
6.2 Improvement Standard 47
7 CONTROL
7.1 Self Inspection Check Sheet 50
7.2 Preventive Maintenance Check Sheet 51

8 CONCLUSION 52

5
 CHAPTER 1 : PREAMBLE

1.1. INRODUCTION

Six Sigma – What is Six Sigma ?

Six Sigma at many organizations simply means a measure of Quality that

strives for near perfection. Six Sigma is a disciplined, data-driven approach and
methodology for eliminating defects (driving towards six standard deviations
between the mean and the nearest specification limit) in any process – from
manufacturing to transactional and from product to service.

The statistical representation of Six Sigma describes quantitatively how a

process is performing. To achieve Six Sigma, a process must not produce more
than 3.4 defects per million opportunities. A Six Sigma effect is defined anything
as outside of customer specifications. A Six Sigma opportunity is then the total
quantity of chances for a defect. Process Sigma can be easily calculated using a
Six Sigma calculator.
The fundamental objective of the Six Sigma methodology is the
implementation of a measurement-based strategy that focuses on process
improvement and variation reduction through the application of Six Sigma
improvement projects. This is accomplished through the use of two Six Sigma
sub-methodologies: DMAIC & DMADV. The Six Sigma DMAIC process
(Define, measure, analyse, improve, control) is an improvement system for
existing processes falling below specification and looking for incremental
improvement. The Six Sigma DMADV process (define, measure, analyse, define,
verify) is an important system used to develop new processes or products at Six
Sigma quality levels. It can also be employed if a current process requires more
than just incremental improvement.

6
 1.2 PROBLEM ON HAND

Cylinder Head Line is one of the Machining Lines in the Engine &
Transmission shop of Hyundai Motor India Ltd. It produces Cylinder Haed of
various models for the i10 & i20 Engines. It has got 47 Machines which are both
of NC & CNC (HMC) types. It is a Mass Production line is this one of the Key
part of the Engine.
The descriptions of the Cylinder Head have been mentioned below :

1.2.1.KAPPA ENGINE:-

7
1.2.2.VIEW OF CYLINDER HEAD:

TOP SIDE VIEW

FRONT SIDE VIEW

REAR SIDE VIEW

IMPROVEMENT AREA

BOTTOM
BOTTOMSIDE
SIDEVIEW
VIEW

1.2.3.CUSTOMER COMPLAINT:

1. Engine Cooling Water Leak From Plugged Hole.

2. More consumption of cooling water.
3. Engine Temperature High.

AFTER PLUGGING

That all parts mentioned above have been Rejected As a Process Rejection.

8
1.2.4.SEALANT APPLY MISS IN PLUG HOLE:

This Project deals with the reduction of the Process Rejection in Cylinder
Head Line, and in specific with the Sealant Apply Miss in plug hole. The term
sealant refers to the Locking solution for avoid the liquid leakage on plugged hole
operation..

SEALANT MISS
(NOT OK)

SEALANT
APPLIED (OK)

9
 1.3 IMPORTANCE OF THE PROBLEM

1.3.1. Pareto chart – Customer Complaint

16.00 91 95 100 100.00

14 85
14.00 78
71 80.00
12.00 11
10 62
10 9
10.00 53 9 60.00
8
44 8
8.00 7
35 6
6.00 5
40.00
25 4
4.00
20.00
2.00 14

0.00 0.00
WATER LEAK HEATER PIPE NOT CAM SHAFT HLA - NOT ENTRY LOOSE BURR ON FRT CAM CAP V/SEAT RUST V/GUIDE RUST CAM BORE LINE EXTRA DELIVARY PIPE OTHER / OLD PR
FROM PLUGGED ENTRY TIGHT ROTATION (TIGHT) CAM BORE AREA TIGHT FOR M ARK M ATERIAL ON OIL M TG AREA
HOLE REM OVEL HOLE AREA DAM AGE

Defect% Over all %

10
1.3.2. Pareto chart – Defect wise
From the above Graph :

35.00 33 90 93 100.00
84 87
78 81 98 100
30.00 75 95
71 80.00
63 67
25.00 58
20.00
60.00
48

15.00 15
40.00
33 10
10.00
5 20.00
4 4 4 4 3 3
5.00 3 3 3 3 2 2

0.00 0.00
Sealant HLA bore Cam M illing Face Dowel Dat um spec Bot Dist ng Fr & Rr face Bore Pos Crack & v/ seat area Thread NG Drill broken Top face Drill dia O/ s Old PR
M iss in Plug Line M ark BoreTool Tool mark Broken NG Damage NG Damage damage unwash
Hole M ark
Defect% Over all %

Major contributed rejections are:

(Period: Jan’08 ~ Nov’08)

Ø Sealant miss in plug hole – 31.22%

Ø Leak from v/Guide – 13.72%

Ø Cam bore line mark – 9.35%

Ø Handling Damage – 5.25%

1.3.3.Approximate Cost Analysis:

Total Cost of Rejection due to these issues – Rs. 31.140 Lac’s

Cost of Rejection / Month – Rs.2.595 lacs

Cost of Rejection / Year – Rs.31.140lacs

11
 1.4 SCOPE OF THE PROJECT

Scope of the this project is to reduce the Customer Complaint and Process

Rejection percentage in Cylinder Head machining line by taking proper corrective

action against major problem.

SIG SIGMA concept is taken as a base to reduce the Customer Complaint

and Process Rejection.

1. DEFINE

2. MEASURE

3. ANALYSE

4. IMPROVE

5. CONTROL

1.4.1. EXPECTED BENEFITS :

1. CUSOMER COMPLAINT WILL REDUCE

2. PRODUCTIVITY INCREASE

3. CUSTOMER SATISFACTION

4. ON TIME DELIVERY

5. MOTIVATION

6. EFFECTIVE UTILISATION OF RESOURCES

7. OVERALL EFFICIENCY WILL INCREASE

8. COST SAVING

9. REDUCTION OF MANUFACTURING COST/TIME.

12
 CHAPTER 2 : DETAILS OF THE ORGANISATION

2.1. INRODUCTION

Hyundai Motor India Limited (HMIL) is a wholly owned subsidiary of Hyundai

Motor Company, South Korea and is the second largest and the fastest growing car
manufacturer in India. HMIL presently markets 18 variants of passenger cars in
six segments. The Santro, i10, i20 in the B segment, Getz in the B+ segment, the
Accent and Verna in the C segment, the Elantra in the D segment, the Sonata
Embera in the E segment and the Tucson in the SUV segment.

Hyundai Motor India, continuing its tradition of being the fastest growing
passenger car manufacturer, registered total sales of 500,000 vehicles in calendar
year (CY) 2008, an increase of 18.5 percent over CY 2007. In the domestic market
it clocked a growth of 18.5 percent a compared to 2007, with 186,174 units, while
overseas sales grew by 17.4 percent, with exports of 13,339 units .

HMIL’s fully integrated state-of-the-art manufacturing plant near Chennai

boasts some of the most advanced production, quality and testing capabilities in
the country. In continuation of its investment in providing the Indian customer
global technology, HMIL is setting up its second plant, which will produce an
additional 300,000 units per annum, raising HMIL’s total production capacity to
102,000 units per annum by end of 2009.

HMIL is investing to expand capacity in line with its positioning as HMC’s global
export hub for compact cars. Apart from expansion of production capacity, HMIL
plans to expand its dealer network, which will be increased from 183 to 250 this
year. And with the company’s greater focus on the quality of its after-sales service,
HMIL’s service network will be expanded to around 1000 in 2010.

13
The year 2008 has been a significant year for Hyundai Motor India. It achieved a
significant milestone by rolling out the fastest 300,000th export car. Hyundai
exports to over 95 countries globally; even as it plans to continue its thrust in
existing export markets, it is gearing up to step up its foray into new markets. The
year just ended also saw Hyundai Motor India attain other milestones such as the
launch of the i10 & i20 and yet another path-breaking record in its young
journey by rolling out the fastest 20,00,000th car . The Hyundai Verna has bagged
some of the most prestigious awards starting with the Overdrive ‘Car Of the Year
2007’, CNBC-TV 18 Autocar ‘Best Value For Money Car 2007’ and
‘Performance Car of the Year 2007’ from Business standard monitoring.

This year i10 won the ‘Executive Car of The Year 2008’ award from Business
Standard Motoring Magazine and NDTV Profit – Car & Bike

HMIL has also been awarded the benchmark ISO 14001 certification for its
sustainable environment management practices.

Hyundai's 7th manufacturing unit outside the parent country is also the group's
largest overseas production base. Even as the project was being conceptualized,
Hyundai Motors India Ltd.(HMIL) was always going to play an important role in
Hyundai Motors Company's international operations.

That the company is fully owned by the parent group and the integrated unit at
Sriperambudur can today roll out cars with almost 85% localized content, bears
testimony that the Indian operations have been put down to play an important role
in Hyundai's goal for the 21st century - to be joint the ranks of the GT-10 (Group
10) Companies.

14
 2.2. THE ORGANISATION

2.2.1. PRODUCTS

SMALL SEGMENT EPSILON ENGINE :

G4HC

The G4HC displaces 1.0 L (999 cc) with a larger 66 mm bore and 73 mm stroke.
Power is 58 hp (43 kW) at 5700 rpm, but torque is up substantially to 81 ft·lbf
(110 N·m) at 3000 rpm.

G4HG

The G4HG is a 1.1 L (1086 cc) version with a 67 mm bore and 77 mm stroke.
Output is 64 hp (48 kW) at 5500 rpm and 9.6 kgf·m (94 N·m) at 3000 rpm.

MIDDLE SEGMENT - ALPHA ENGINE :

1.3 L GETZ

The G4EH is a 1.3 L engine. Output was 71 hp (53 kW) at 5500 rpm and 81 ft·lbf
(110 N·m) at 3000 rpm for the carbureted 1.3 CON version and 83 hp (62 kW) at
5500 rpm and 86 ft·lbf (117 N·m) at 3000 rpm for the SOHC 1.3 S.

1.5 L ACCENT

The G4EK is a 1.5 L engine. The SOHC 1.5 S generated a respectable but not
notable 92 hp (69 kW) at 5500 rpm and 97 ft·lbf (132 N·m) at 4000 rpm, although
some websites quote the torque rating as being 97 ft·lbf (132 N·m) at 2700 rpm.
European version makes 90 HP (66 kW) at 5500 RPM and 129 (or 132) Nm at
2900 (or 3000) RPM (try it and you'll see it's true).

DOHC on the Alpha II pushed output to 101 hp (75 kW) at 5800 RPM and
98 ft·lbf (133 N·m) at 3000 rpm.

The turbocharged Alpha, also introduced in 1993, produced 115 hp (86 kW) at
5500 rpm and 123 ft·lbf (167 N·m) at 4500 rpm.

15
1.6 L ACCENT VIVA

The alpha family continued at least through 2005 in Hyundai's Accent economy
car. The G4ED Alpha II was enlarged to 1.6 L (1599 cc) thanks to a 76.5 mm bore
and 87 mm stroke. A 10:1 compression ratio produced 104 hp (78 kW) at
5800 rpm with 106 ft·lbf (144 N·m) of torque at 3000 rpm.

The Alpha II has a cast iron engine block and aluminum DOHC cylinder heads
with 4 valves per cylinder. It uses MFI fuel injection and features forged steel
connecting rods. The Alpha engine family is produced in Ulsan, South Korea.

CVVT Alpha II was introduced in the 2006 Accent. Power output also increased
to 112 PS and 108 lb/ft torque. It has COP(Coil-On-Plug) ignition, graphite-coated
pistons and new cylinder block design to increase strength. Throttle body bore has
increased from 48 to 52 mm. Engine and automatic transmission control is now
integrated into one module and the PCM is located in the engine compartment. It
is ULEV-certified in all 50 states.

2.0 L SONATA

The G4GF (also called the 2.0 D) is the 2.0L (1975cc) version. It shares the larger
82mm bore of the 1.8 but is stroked to 93.5 mm. It has a cast iron engine block and
aluminum DOHC cylinder heads. It uses MFI fuel injection, has 4 valves per
cylinder and features forged steel connecting rods. Output is 140 hp (104 kW) at
6000 rpm and 133 foot pounds of torque (180 N·m) at 4800 rpm.

16
Beta II ELANTRA

During 2001-2002, the new Beta II engine made its debut in models such as the
XD Elantra and GK Tiburon. Output is 138 hp (102 kW) at 6000 RPM with 136
foot pounds of torque (184 N·m) at 4500 RPM. It has a cast iron engine block and
aluminum DOHC cylinder heads. The latest version of the 2.0L Beta engine
(G4GC) features CVVT, which only in intake side, a first for Hyundai/Kia. The
following changes were noted.

• Redesigned block with external contouring of cylinder bores (ilo flat sides), extra
ribbing & one extra transaxle fixing point (now 5)(less NVH)
• Crankshaft now has 8 counterweights ilo 4.(NVH)
• Cast & ribbed aluminium sump pan (ilo pressed steel sheet) with stronger joint to
transaxle (NVH)
• 20mm longer intake rams, 8% smaller surge tank, resonator added, spark timing
& valve lift optimized, lighter valve springs, denser conrod bearings, returnless
fuel system (ilo return type) with higher fuel pressure & smaller injectors (torque
spread & econ)
• Cylinder head machined to more precise tolerances
• Head gasket now 2-layer (ilo 3)
• Idle speed reduced to 700 rpm from 800 rpm (NVH)
• Hydraulic engine mounts (4) ilo rubber (NVH)
• Heat shield installed between engine & air filter, reducing heating of induction
air (+2% output).
• New camcover with I-piece high-specific gravity polypropylene baffle (ilo 2-
piece pp)
• Oil flow reduced (econ)
• Mechanical valve lash adjusters (solid lifters) replace hydraulic, improving valve
clearance precision (durability).
• Lower valve spring load reduces valve train friction (perf).
• Engine cover installed (NVH & dress up engine bay)
• Catalytic converter now upstream adjoining exhaust manifold (ilo under car)
(emissions)
• Other detail changes to: alternator, intake manifold brace, power steering & a/c
pulleys, idle speed actuator, oil filler cap & drive plate between engine & torque
converter

17
2.2.2.PROCESSES:

The Press Shop

A computer controlled line that converts sheet metal to body panels of high
dimensional accuracy and consistency.
Process : Blanking, Shearing & Stamping

The Body Shop

A hi-tech line that builds full body shells from panels. Automated robotic arms are
used for intricate welding operations that ensure superior and consistent build
quality.
Process : Spot Welding, Projection Welding & Co2 Welding

The Paint Shop

This is one of the most modern paint shops in the country and uses the
environment friendly water based process for superior and lasting exteriors. A
unique process management system followed here helps us deliver the most
extensive colour range, independent of minimum batch requirements, helping
customers get their preferred colour anytime.
Process: Pre-Coating, Phosphate & ED Painting

The Aluminium Foundry

Forges the engine cylinder blocks for our cars to exacting design specifications.
Process : Cylinder Head Casting

The Engine and Transmission Shop

One of the biggest engine shops in the country, this unit is equipped with the most
modern tooling and testing facilities to make a wide range of engines inhouse.
Process : Machining, Heat Treatment & Eng & TM Assembly

Vehicle Assembly Shop

One of the biggest Vehicle shops in the country, this unit is equipped with the
most modern facilities to make a wide range of Vehicles
Process : Assembly & Testing of Vehicles

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The Plastic Extrusion Unit
Moulds the dashes, bumpers and other plastic components to perfect fit and finish.
Process : Moulding & Sub Assembly

The Plastic Paint Shop

One of the very few manufacturing units in India to have this facility in-house,
Hyundai's plastic paint shop delivers a high grade finish on exterior plastic
components.
Process : Spray Painting of Bumpers.

Heat Treatment
One of the very few Heat Treatment units in India to have this facility in-house,
Hyundai’s Heat treatment division is to get hardened parts for Transmission assy
Like Shafts, Speed gears
Process : Carburising , Quenching , Shot Blasting

19
2.2.3. FACILITIES

The Test Track

With comprehensive performance testing facilities like rattle testing and ABS
brake testing, this track is designed to meet pre-delivery (PDI) certification
standards to exacting Euro specifications.

R&D
Hyundai and Kia together have R&D centres in the United States, Europe,
Japan apart from the global R&D headquarters at Ulsan, Korea.

The Hyundai Motor Group has recently dedicated an annual R&D spend of
close to US$ 2 Billion, up from US$ 1.2 Billion to enhance its thrust on new
product development and achieve global quality benchmarks by year 2005. This
includes the $30 Mn Hyundai-Kia Design and Technical Center in Irvive,
California.

The R&D team focuses on the development of new products and technologies that
include interior and exterior design changes, development of new generation
engines and alternate fuel systems, concept vehicles and advanced passenger
safety and comfort systems, in line with evolving customer preferences across the
globe. Recent successes of the team include the development of the Hyundai
patented Common Rail Direct Injection (CRDi) engine in association with Detroit
Diesel and the award winning Fuel Cell Santa FE.

Some of the ongoing projects that the Hyundai R&D team is involved in include
the development of the 'World Engine' in association with Daimler Chrysler and
Mitsubishi and the development of Automotive Telematics in association with
IBM.
That the efforts of the Hyundai R&D team has paid great dividends to the
company is evident from the fact that the company's newly engineered products
like the Santa Fe and the Getz have made waves in the global automotive markets
and the 'US Consumer Reports' magazine has ranked Hyundai cars in level with
that of Honda in its recent quality rankings

20
2.2.4. ORGANIZATION STRUCTURE

Managing Director

Executive Executive Executiv

Director Director Director

Plant Head

Group Head Group Head Group Head Group Head

Press & Body Paint shop Veh Assy Eng & TM

Dept Heads Dept Heads Dept Heads Dept Heads

Section Heads Section Heads Section Heads Section Heads

Asst.Manager Asst.Manager Asst.Manager Asst.Manager

Sr. Engineers / Sr. Engineers / Sr. Engineers / Sr. Engineers /

Tech Tech Tech Tech
Associates Associates Associates Associates

Technicians & Technicians & Technicians & Technicians &

Apprentices Apprentices Apprentices Apprentices

21
 2.3.ORAGANISATIONAL BUSINESS PROFILE

The Hyundai India plant located in Irungattukottai, 30 kilometres from Chennai

was built in record time. The plant is first self-sufficient manufacturing unit in
India to be independently invested by an overseas automobile company.
Incorporated in May 1996, the groundbreaking ceremony for the Chennai plant
was held in December in the same year, and the first pilot Santro was ready in a
record-breaking 17 months.

The plant which stands on a 500+acre plot has been built with an initial investment
of more than Rs. 2500 crores. It has a capacity to make 120,000 cars and 130,000
engine transmission units per annum and is the largest overseas investment made
by the Korean Company.

HMIL commenced operations with 70%-localized content, which is one of the

highest amongst all car manufacturers. The entire powertrain and the body panels
are made in-house and the integrated manufacturing setup at the Hyundai Motors
Chennai plants consists of:

Hitachi Zosen 2500 ton presses for the body panels

State-of-the-art Paint shop
Final assembly line
Engine and transmission lines
Aluminium foundry Plastic extrusion unit
In-house R&D Centre

Hyundai has brought in 14 Korean companies and helped them setup base in India
for sourcing components. The total vendor base consists of 60 companies located
at the plant site itself. HMIL aims to increase localized content to over 90% in the
millennium.

22
The Present

Although the HMIL is said to have initially planned to launch their Indian
operation with a car for the mid-sized segment, the company changed policies and
introduced the Santro for the small car market. A decision which in hindsight,
seems to have paid handsome dividends.

A formal study was commissioned by Hyundai prior to the launch of the Santro, to
gauge the - as Mr. Leeham, Director Marketing & Sales says-so-stated" needs of
the Indian small car buyer. Several factors right from the design of the car, the

cooling of the AC, and the dealer network have been on the basis of the study so
as to present to the people the kind of car that they want and need. The Santro has
been designed by in-house Hyundai expertise.

Modeled on the Hyundai Atos, the Mercedes A140 and Suzuki's Wagon R, and
then customized to Indian tastes, the Santro takes the best of all the cars viz. the
driveability of the Atos, the safety & design of the Mercedes A140, and roominess
of the Wagon R.

The Santro (which is available in three variants - the L2, GLS1 and GLS2) was
launched in September 1998, and the company has targeted a production of 60,000
Santros per year. With sales of 30,000 vehicles in the last eight months HMIL
seems to be fairly on target.

The monthly sales of the Santro (from October 98 to August '99 are given below)

Month Oct Nov Dec Jan Feb Mar Apr May June
Units 1123 3444 3881 2753 2157 4290 3531 4519 4634
Month July August Hyundai Santro has captured 30%of the market share in the
small car segment and 10% in the overall auto industy
Units 4,949 7002

The cumulative sales of the Hyundai Santro( Oct '98-Aug '99) are 42,283 units.

23
The Future

Hyundai Motors India Ltd. plans to build a world-class facility, which will offer
quality products and services to the discerning consumer. It plans to enforce the "
global optimum production system", setting its goal to achieve the utmost result
with the lowest running cost.

The Indian operations will play an important role for Hyundai to develop and
expand their presence in the neighboring South East Asian countries and plans to
export the Santro as SKDs (semi-knockdown kits) and CBUs (completely built
units) to the neighboring countries like Pakistan, Bangladesh, Nepal and Sri
Lanka.

In fact the Santro has been launched in its parent country under a new name the
Visto The body panels and the engine as well as the transmission components are
entirely imported from India, and the Visto is being assembled by HMC at their
Ulsan Plant. By doing so HMIL has created a record of sorts. As Mr. BVR Subbu,
managing director of HMIL says "This is first time in the history of the Indian
passenger car industry that an international product has first made its debut in the
Indian market and then taken from its shores to parent company's domestic
market"

The company also has plans to introduce several new models in the Indian market,
and the pre-production and road tests of its next car are already being conducted.
Code-named the LC-I, HMIL plans to introduce a mid-sized (1400 - 1800 cc) car
in October 1999. Although similar to the Hyundai Accent which already sells in
Korea, the LC-1 (like its predecessor the Santro) has been specially designed for
the Indian market at the Hyundai Design Centre at Namyong, Korea. The
company also plans to launch at a later date a multi-utility vehicle in the Indian
market. By the year 2008 HMIL will employ around 3000 workers operating in
multiple shifts.

24
 2.4. OTHER RELEVANT INFORMATION

PARENT COMPANY ( HMC, KOREA )

Established in 1967, Hyundai Motor Co. has grown into the Hyundai Kia
Automotive Group which includes Hyundai Mobis and over two dozen auto-
related subsidiaries and affiliates. Employing over 68,000 people worldwide,
Hyundai Motor posted US$27.383 billion in sales in 2005 (on a non-consolidated
basis). Hyundai motor vehicles are sold in 193 countries through some 5000
dealerships and showrooms. Hyundai Motor Co. is a sponsor of the 2006 FIFA
Germany World Cup. Further information about Hyundai Motor Co. and its
products is available

2.5. CONCLUSION

Hyundai today enjoys a market share of around 20% and is looking at the doubling
that figure. Given the Indian market's response to the Santro & i10, the company
seems to be well on course....
v Best customer service
v Best technology Fully Automated Engine shop.
v Best quality products

25
 CHAPTER 3: DEFINE

Define the Goals of the Improvement

Activity. At the Project level goals might be to
reduce the defect level and increase throughput.
Apply data mining methods to identify potential
improvement opportunities.
Problem Definition

In this project the Cylinder Head line has been taken for study due to
its high rejection trend in the last 1 year. The top three problems related to the
rejection will be summarised and one problem will be solved using the DMAIC
concept.
The following tabulations show the rejection trend of each component; the
cost wise rejection details and an exhaustive rejection trend of Cylinder Head line
The Process flow diagram for the Cylinder Head machining line has also
been given below to know the overall Production sequence and the product
characteristics varying due to the incoming sources of variation. The diagram also
shows the Process characteristics for each and every stage of production.

The Cause and Effect diagram for the Cylinder Head – Sealant Miss
has also been given below. The sources of variation due to Man. Machine,
Material and Method has been depicted.

26
 3.1.CUSTOMER COMPLAINT DETAILS

16.00 91 95 100 100.00

14 85
D 14.00 78
E 71 80.00
12.00 11
F 10 62
10 9
E 10.00 53 9 8 60.00
C 44 8
T 8.00 7
S 35 6
6.00 5
40.00
25 4
i 4.00
n 20.00
2.00 14
%
0.00 0.00
WATER LEAK HEATER PIPE NOT CAM SHAFT HLA - NOT ENTRY LOOSE BURR ON FRT CAM CAP V/SEAT RUST V/GUIDE RUST CAM BORE LINE EXTRA DELIVARY PIPE OTHER / OLD PR
FROM PLUGGED ENTRY TIGHT ROTATION (TIGHT) CAM BORE AREA TIGHT FOR M ARK M ATERIAL ON OIL M TG AREA
HOLE REM OVEL HOLE AREA DAM AGE

Defect% Over all %

Water Leak Is contributes 14% in overall Customer

Complaint
CUSTOMER COMPLAINT DUE TO SEALANT MISS DUE TO
SEALANT MISS IN TERM OF PPM FOR THE

PERIOD OF JUL’08 – MAY’09 = 745.88ppm

27
 3.2.PRODUCTION & REJECTION DETAILS

PRODUCTION QTY. TOTAL

TOTAL
PART DESCRIPTION JUL’08~
REJECTION
AUG '09 SEP'09 PRODUCTION
JUL’09
QTY.

CYLINDER HEAD 210611 8060 9094 227765 7230

CYLINDER BLOCK 161117 7967 8100 177184 3689
CRANK SHAFT 151961 9757 11780 173498 9272
CAM SHAFT 150650 17004 18732 186386 1502
CON. ROD 142418 6547 7468 156433 5610
TOTAL 816757 49335 55174 860266 23

COST OF REJECTION (Rs.) % REJ.

% REJ.
BASED
BASED
RAW MTL. PROCESS UNIT TOTAL ON CUML. % PPM
ON
COST COST COST COST OVERALL
PROD.
REJ.
1508 603 2111 13341520 3.79% 24.28% 24.28% 37898
954 846 1800 6640200 2.08% 13.34% 37.62% 20820
445 610 1055 9781960 5.34% 34.24% 71.86% 53442
160 123 283 425066 0.81% 5.16% 77.02% 8059
436 332 768 4308480 3.59% 22.98% 100.00% 35862
3503 2514 6017 34497226 15.61% 100.00% 156080

1200000 100.0% 100%

1102475
90%
949950 86.4%
81.9% 80%
900000 813600
REJ. COST (RS.)

70%
% REJ. CUML.

60%
600000 50.4% 50%
476160
40%
30%
300000 27.2%
156216 20%
10%
0 0%
CYL. HEAD CYL. BLOCK CRANK SFT. CAM SFT. CON. ROD

COMPONENT NAME

28
 3.3.COSTWISE REJECTION DETAILS

COST OF POOR
TOTAL % OF
QUALITY
PART DESCRIPTION REJECTION TOTAL CUML. %
TOTAL
QTY. UNIT COST COST
COST

1512215
6821 2217 41.50% 41.50%
CYLINDER HEAD 7

CYLINDER BLOCK 2514 1833 4608162 12.65% 54.14%

1041970
CRANK SHAFT 7858 1326 28.59% 82.74%
8

CAM SHAFT 1433 283 405539 1.11% 83.85%

CON. ROD 5909 996 5885364 16.15% 100.00%

3644093
TOTAL 24535 6655 100.00%
0

3.3. COSTWISE REJECTION DETAILS

Cost
16000000 15122157

10419708
Cost in Lacs

5885364
4608162
6000000
405539

-4000000
CYLINDER HEAD CYLINDER BLOCK CRANK SHAFT CAM SHAFT CON. ROD

Cost 15122157 4608162 10419708 405539 5885364

29
 3.4. PROCESS REJECTION TREND – CYLINDER HEAD LINE

35.00 33 90 93 100.00
84 87
78 81 98 100
30.00 75 95
71 80.00
63 67
25.00 58
20.00
60.00
48

15.00 15
40.00
33 10
10.00
5 20.00
4 4 4 4 3 3
5.00 3 3 3 3 2 2

0.00 0.00
SEALANT HLA BORE CAM BORE M ILLING DOWEL DATUM BOT DIST NG FRT & REAR BORE CRAKE & V/SEAT THREAD DRILL TOP FACE DRILL DIA OTHERS
M ISS IN PLUG LINE M ARK TOOL M ARK FACE TOOL BROKEN SPEC NG FACE POSITION NG DAM AGE AREA DAM AGE BROKEN UNWASH O/S
HOLE M ARK DAM AGE DAM AGE

Defect% Over all %

From the above Graph:

Major Top 3 contributed rejections are:

(Period: Jul’08 ~ May’09)

Ø Sealant Miss in Plug Hole – 33.22 %

Ø HLA Bore Line Mark – 13.72 %
Ø Cam Bore Tool Mark – 9.35 %

30
Approximate Cost Analysis of Top 3 Major Problems :

Total Cost of Rejection due to these issues / Qtr – Rs.23.37 Lac’s

Cost of Rejection / Month – Rs.7.8 lac’s

Cost of Rejection / Year – Rs. 93.48 lac’s

Hence, I am going to analyse the Major contribution of Sealant

Miss in Plug Hole Problem in Cylinder Head
Approximate Cost Analysis for Sealant Miss Problem:-

Total Cost of Rejection due to Sealant Missing / Qtr – Rs. 21.5 Lac’s

Cost of Rejection / Month – Rs.4.48 lac’s

Cost of Rejection / Year– Rs. 53.8 lacs

31
LAY OUT – KAPPA CYLINDER 3.4.1.CYLINDER HEAD LINE – LAYOUT
HEAD LINE

IE GB20 -170

MAIN GANG WAY

32
3.4.2. PROCESS FLOW DIAGRAM

33
34
35
36
WHAT IS MEAN BY SEALANT?

SEALANT IS NOTHING BUT ONE TYPE OF LOC TITE.IT WILL BE USED FOR

BLOCK THE SMALL HOLES.

SPECIFICATION:-

TYPE : LOC TITE 962

COLOUR : RED

CONTINER CAPACITY : 1LITRE

WHAT IS MEAN BY PLUG?

PLUG IS NOTHING BUT ONE OF THE METAL CAP THAT PRODUCED BY PRESSING

OPERATION.THIS OUTER DIA METER WILL BE VARIED DEPEND UPON APPLICATION.

TOP SIDE VIEW BOTTOM SIDE VIEW

PRESSING DIRECTION

Dia28mm SIDE VIEW

Dia32
mm

37
IE GB20 – 170 M/C PROCESS DETAILS:

1.PART INPUT

CYLINDER HEAD MOVING

ON CONVEYOR

2.SEALANT APPLY IN PLUG HOLE

CYL.HEAD

ROBOT

SEALANT APPLY CYL.HEAD AFTER APPLY

BY ROBOT THE SEALANT

3.PLUG PRESS BY HYD.PRESS

HYD.PRESS

PLUG PRESSING CYLINDER AFTER PLUG

BY HYD PRESS PRESS

38
 CHAPTER 4: MEASURE

Measure the existing system. Establish valid

and reliable metrics to help monitor progress towards
the goal(s) defined at the previous step. Begin by
determining the current baseline. Use exploratory and
descriptive data analysis to help you understand the
data.

Critical Process affecting the Sealant Apply Miss:-

v Incoming Source of Variation

v Critical to Process characteristics

v Machine Maintenance Frequency

v Sealant change frequency & Setting

v Critical Tools

v Other Product Quality affecting Parameters

v Process & Machine Capability

39
4.1. INCOMING SOURCE OF VARIATION:

40
 CHAPTER 5 : ANALYSE

Analyse the System to identify ways to eliminate the

gap between the current performance of the system or
process and the desired goal. Apply statistical tools to
guide the Analysis.

The various statistical tools that can be implemented for analysing the problems
are shown below:

a. Sources of variation

b. Hypothesis testing

c. Root cause analysis

d. Process mapping

e. Graphical techniques

f. Correlation techniques and

g. Multi variable charts

Of the above mentioned tools the Scatter diagram method of analysis has been
taken up in the study.

41
5.1.CAUSE & EFFECT DIAGRAM - I

1. a.Cause & Effect Diagram

1.b. 5 Why Analysis :

1. Datum Position shift in Cylinder block,
2. Shift due to un-even clamping / butting of the component
3. Raw material distance variation,
4. Raw Material Casting variation.
5. Casting variation due different supplier.

2. Effect of Knock hole Drilling Posn. On Reaming Posn. (#40) :

42
5.2. 4M ANALYSIS FOR SEALANT MISS

43
5.3.CAUSE & EFFECT DIAGRAM - II

44
 CHAPTER 6: IMPROVE

Improve the system. Be creative in finding new

ways to do things better, cheaper or faster. Use
Project management and other planning and
management tools to implement the new approach.
Use statistical methods to validate the improvement.

The tools which are being used here are:

a. Design of experiments

b. Simulation

c. Optimization

d. Change management

e. Strategy of experimentation

The various problems analysed have been given solutions based on the
requirements. The improvements have been taken in the following categories:

a. Man

b. Machine

c. Material

d. Method

45
 6.1 ACTION FOR MAJOR CAUSES

We have found the following root causes for the Sealant Missing.
From 4M analysis.
6.1.1. Incoming air pressure drop for Sealant Supply Unit.
6.1.2. No Inspection
6.1.3. No Detect / Preventive Mechanism (Mistake Proof)
6.1.4. No Control System for Hourly Inspection.

Root cause: Incoming air pressure drop for Sealant Supply Unit.
Action Taken:
ALARM MASSAGE HAVE BEEN CREATED IN M/C PLC.WHENEVER THE AIR
PRESSURE DROP MASSAGE WILL DISPLAY AS “AIR PRESSURE DROP “. AS WEL AS M/C PROCESS
WILL NOT START.

Root cause: No Inspection after Sealant applies.

Action Taken:
AWARNESS TRAINING HAVE BEEN GIVEN TO STAGE OPERATOR TO CHECK
THE SEALANT CONDITION VISULLY IN ALL CYLINDER HEAD. ONE MANPOWER DIPLOYED
FOR 100% INSPECTION.

Root cause: No Detect / Preventive Mechanism (Mistake Proof)

Action Taken:
AUTOMATIC SEALANT CHECKS SENSOR HAS BEEN PROVIDED.TO CHECK
SEALAT CONDITION 100%.AS WELL AS TO ELIMINATE ONE MAN POWER WHO IS DOING
INSPECTION MANUALLY.

Root cause: No Control System for Hourly Inspection.

Action Taken:
HOURLY INSPECTION CHECK SHEET HAVE BEEN PROVIDED TO ENSURE
THE HOURLY INSPECTION STATUS BY STAGE OPERATOR.

46
 6.2 IMPROVEMENT STANDARD

6.2.1. IMPROVEMENT SHEET -I

47
6.2.2. IMPROVEMENT SHEET – II

48
 CHAPTER 7: CONTROL

Control the New system. Institutionalize the

improved system by modifying compensation and
sincentive systems, policies, procedures, MRP
Budgets, Operating Instructions and other
management Systems. You may wish to utilize systems
such as ISO 9000 to assure that documentation is
correct.

The tools which are being used here are:

a. Self Inspection Check Sheet.

b. Preventive Maintenance Sheet Updated For Detection Mechanism.

c. POKA YOKE / Mistake proofing

d. Gauge control plan and

e. Other Control plans

49
7.1 SELF INSPECTION CHECK SHEET

50
7.2. PREVENTIVE MAINTENANCE CHECK SHEET

51
 CHAPTER 8: CONCLUSION

The DMAIC concepts has been used in the Cylinder Head machining line
for reducing the Customer Complaint & Process Rejection due to Sealant Missing
in Plug Hole. Problem has been targeted and solutions taken. The Improvements
are and the analysis done during the Project. The Control Plan has been formulated
so as to avoid based on the study the Customer Complaint and Process Rejection
due to Sealant Missing in Plug Hole.

The details of the Customer Trend and PR Trend have been given below
which shows for itself the reduction in the PR due to Sealant Missing in Plug
Hole.

CUSTOMER COMPLAINT TREND - WATER LEAK

160
144 Action taken
140

120

zero
QTY IN N OS

100

80

60

40
21 24
20 12 14
0 0
0
JUL'08 - JUN'09 JUL'09 AUG'09 SEP'09 OCT'09 NOV'09
MAY09

MONTH

52
PROCESS REJECTION TREND AFTER IMPROVEMENT:

PROCESS REJECTION TREND - SEALANT MISS

1200
1095

1000

800
QTY IN NOS

600
zero
400

200
65 45
32 34 12 0
0
JUL'08 - JUN'09 JUL'09 AUG'09 SEP'09 OCT'09 NOV'09
MAY09

MONTH

53
 BIBLIOGRAPHY

SUNG .H. PARK, Six Sigma for Quality and Productivity,

Asian Productivity organization - Japan, Second Edition 2003.

AMITVA, Fundamental of Quality Control Improvement,

Mitra Publishers, Second Edition 2001.

EVERALD .E. ADAM, Production and Operation Management,

Ronald Publication, Fifth Edition 2001.

www.isixsigma.com

www.whatis.techtarget.com

www.qualitydigest.com

54
 Checklist of items for the Final Project Work Report

Is the report properly hard bound? Spiral bound, soft bound reports are not Yes / No
1.
acceptable.
2. Is the Cover page in proper format as given in Annexure A? Yes / No

3. Is the Title page (Inner cover page) in proper format?

Yes / No
(a) Is the Certificate from the Supervisor in proper format? Yes / No
4.
(b) Has it been signed by the Supervisor? Yes / No
Is the Abstract included in the report properly written within one page? Have the
5. Yes / No
keywords been specified properly?
Yes / No
Is the title of your report appropriate? The title should be adequately descriptive, precise
6. Yes / No
and must reflect scope of the actual work done.

Have you included the List of abbreviations / Acronyms? Uncommon abbreviations /

7. Yes / No
Acronyms should not be used in the title.

8. Does the Report contain a summary of the literature survey?

Yes / No
Does the Table of Contents include page numbers?
iAre the Pages numbered properly? Yes / No
Are the Figures numbered properly? (Figure Numbers and Figure Titles at the bottom of
the figures) Yes / No
9.
Are the Tables numbered properly? (Table Numbers and Table Titles at the top of the
tables) Yes / No
Are the Captions for the Figures and Tables proper? Yes / No
Are the Appendices numbered properly? Yes / No

10. Is the conclusion of the Report based on discussion of the work?

Yes / No
Are References or Bibliography given at the end of the Report? Yes / No
11. Have the References been cited properly inside the text of the Report?
Yes / No
Is the citation of References in proper format?
Yes / No
Have you written your report according to the guidelines? The report should not be a
12. Yes / No
mere printout of a Power Point Presentation. Source code need not be included in the
report.

A Compact Disk (CD) containing the softcopy of the Final Report and a copy of the Final Yes / No

Seminar Presentation made to the Supervisor / Examiner (both preferably in PDF format
13.
only) has been placed in a protective jacket securely fastened to the inner back cover of

the Final Report. Please write your name and ID No with a marker on the CD as

well as the CD Jacket.

Declaration by Student:
I certify that I have properly verified all the items in this checklist and ensure that the report is in
proper format as specified in the course handout. __________________
Place: CHENNAI Signature of the student
Date: ______ Name: A.MARIMUTHU
ID No.: 200618TS246

55