Delivery Performance Improvement of An Automotive Part Using DMAIC Approach

Final Project Presentation
Delivery Performance Improvement of an

Automotive Part using DMAIC Approach
Sreejesh SP
BUB0412005 PT12
M. Sc. [Engg.] in Engineering and Manufacturing Management
Academic Guide : Industrial Guide :

Mr. Vijaya Kumar S Mr. Subash Sundar
Asst. Prof, MSRUAS Asst. Manager, Production
Team Concepts. Pvt. Ltd
1
M.S.Ramaiah School of Advanced Studies
Aim of the project
To improve delivery performance of roof rail

by 30% using DMAIC approach
2
Project objectives
To carryout literature survey on delivery performance, painting,

aluminum finishing process, first pass yield improvement, DMAIC
To understand current process flow and monitor datas
To identify root causes of problem using QC tools
To suggest and implement appropriate solutions to reduce the
rejection level
To standardize the process for sustenance
3
Methods and Methodologies
Literature survey carried out for delivery performance, painting,
aluminum finishing process, first pass yield improvement, DMAIC
referring journals, publications, books and other related documents.
The details of existing process flow collected from process flow

diagram ( PFD)
Gemba study carried out to understand the process requirements and

to identify the possible reason for rejections from process engineers and
operators
4
Methods and Methodologies
Collected the rejection/rework data from team by using QC tools
and technique and root cause was found by why-why analysis
Appropriate solution for each problems found
Validation of the implemented solution and standardization done

by generations of operating standards
Horizontal deployment on other running roof rail projects ( Ford

Figo roof rail)- Proposal
5
Place of work
Team Concepts Pvt. Ltd.

#1A/07, 2nd Floor, East End Main road,
Jayanagar 4th 'T' Block, Bangalore
Karnataka - 560041.
6
Introduction
Products of Team Concepts Pvt. Ltd.

Literature Review
Sl no Author Papers Topic
Joseph H. Berk, J.H. Delivery Performance Improvement
1 Berk and Associates 6 Ps for Improved Delivery Performance
Factor model of manufacturing difficulties , First pass

2 A conceptual model for manufacturing
M.A. Karim
performance improvement yield
Ranjan Raj,
On-Time Delivery Improvement Using Lean
3 Dr. B.P.Mahesh Concepts - A Case Study of Norglide Bearings Value stream mapping , Lead time, Kanban
Sandesh S
Seema Banu, Improving First Pass Yield and Reducing Defect
Six Sigma, First Pass Yield, Design of
4 M Rajesh Cost of Honing Machine Using Six Sigma
Experiments,DMAIC
, G S Prakash Approach
I.B. Silva, G.F. Batalha Integrated product and process system with
5 M. Stipkovik Filho c, continuous improvement in the auto parts Quality System; CIM; DFMA; Lean Six Sigma
F.Z. Ceccarelli , J.B. industry
Anjos , M. Fesz
De Mast J and International Journal of Production Economics Six Sigma DMAIC method from the perspective of
6
Lokkerbol J 139(2) 604614. problem solving
IOSR Journal of Mechanical and civil
DMAIC methodology for increasing quality in textile
7 Neha Gupra engineering (IOSR-JSME) 2278-1684 Volume
industry
6, PP 50-65
8
Literature Review
Joseph H. Berk, J.H. Berk and Associates
Experience indicates that in MRP-based manufacturing organizations, delivery delinquencies are
systemically driven by failures to understand and abide by lead times, failures to address capacity
constraints, ignoring manufacturing productivity, diffused organizational responsibilities for on-time
delivery performance, internal procurement failures, and non-robust processes.
Recommendations for delivery performance improvement include understanding the nature of the
capacity/load/lead time relationship, developing meaningful lead times, and only departing from lead
times with supporting reschedules and focused management.
M.A. Karim
As per author product quality and reliability is the main competitive factor for manufacturers.
Design and manufacturing capability and on time delivery came second. Price is considered as the
least important factor for the Australian manufacturers.
9
Literature Review
Results show that collectively the advanced quality practices proposed in this study neutralize the
difficulties manufacturers face and contribute to the most performance objectives of the manufacturers.
The results validate the proposed conceptual model and lend credence to hypothesis that proposed
relationship between quality practices, manufacturing difficulties and manufacturing performances.
Ranjan Raj Urs S, Dr. B.P.Mahesh, Sandesh S

The paper outlines how On-Time Delivery is to be improved by using Lean concepts. For this
purpose lean tools are used because lean focus on the continuous improvement of a company towards
the ideal through the relentless reduction of waste.
Lean tool such as Value Stream Mapping are used to reduce Lead time. We have studied production
process of one product and drawn the current state value stream map. From the current data analysis
found out the problems as high Lead time and Inventory.
Implemented Kanban system to reduce the lead time, Inventory and provide a future state value
stream map. Production schedule is fixed and by this On-time Delivery is Improved.
10
Literature review summary
Seema Banu, M Rajesh, G S Prakash
This paper focuses on the use of Six Sigma approach to improve the First Pass yield
(FPY) of honing machine.
Six Sigma is a disciplined method of using extremely rigorous data gathering and
statistical analysis to pinpoint sources of errors and ways of eliminating them.
The main focus of this work is to reduce potential process variations and reach the six
sigma quality level.
FPY is an important manufacturing metric for measuring quality and production
performance.
I.B. Silva, G.F. Batalha M. Stipkovik Filho c, F.Z. Ceccarelli , J.B. Anjos , M.
Fesz
Paper shows what the problems are during the factory quality system management.
11
The results achieved in the studied company show the performance quality evolution
through their indicators. Furthermore, the QSF (Quality System Final) produced not only a
"correction of problems", but an elimination of the "root causes" to ensure the discipline
requirements of the system with emphasis on continuous improvement to achieve quality
assurance in the supply chain.
De Mast J and Lokkerbol J.

According to this paper, Six Sigma is defined as an organized and systematic method for
strategic process improvement and new product and service development that relies on statistical
methods and the scientific method to make dramatic reductions in customer defined defect rates.
Six Sigmas structured improvement procedure is seen as a novel and effective contribution to
quality management.
12
Neha Gupta
DMAIC is a systematic six-sigma project management practice inspired by Deming's

PDCA (Plan, Do, Check, and Act) Cycle. The process consists of the five phases called
Define, Measure, Analyze, Improve and control. Six Sigma, on the other hand, is a data
driven methodology used to identify root causes for variations in a production process in
order to achieve organizational excellence.
13
DEFINE PHASE
14
Problem identification
Problem Background :
Monthly OEM Sales in %

5%
10% Toyota
Nissan
10% 45% Renault
MSIL
15% M&M
FORD
15%
Toyota Monthly Sales in % Split -
Up
5%
5% 5% 860 A ROOF RAIL
Innova RR Bull Guard
5% Innova Spoiler BMC
50% 860 A BCP
15%
Corolla Altis CBP
Innova CBP
15% Innova fender Pole
15
Defining the problem
Problem Background :
860A roof rail Sale order Vs Delivery
Roof Rail Delivery performance for April and May 2014

Sales Order (Nos) Delivered (Nos) In Percetage (%)
14-Apr 1800 1254 69.7
14-May 1728 1190 68.9
Business Loss Of Rs.27 Lakhs
16
Target of the project
GOAL Set a Target
70% 100%
Delivery
17
Component details
3 5
4
2
1 7
6

Component details contd.
Part No./Dwg Raw Material Process
Sl No1 Part Name Qty Process done
No. Specs Invovled
PLATE ROOF RACK SUPPORT
1 63441-0D020-B ASA 1 Mouding Inhouse
NO.1
Moulding- Inhouse+
2 63443-0D020 PROTECTOR ROOF RACK FR RH ABS 1
Painting supplier
Bending,
Cutting, drilling. Inhouse+
3 63447-0D020-B BAR, ROOF CARRIER RH Aluminium 1
Buffing, supplier
painting
4 63471-0D010-D LEG, ROOF RACK FR RH Aluminium 1 Casting Supplier
5 63473-0D010-G LEG, ROOF RACK RR RH Aluminium 1 Casting Supplier
6 63486-0D020 CUSHION ROOF RACK LEG FR RH EPDM 1 Moulding Supplier
7 63488-0D020-A CUSHION ROOF RACK LEG RR RH EPDM 1 Moulding Supplier
PLATE ROOF RACK SUPPORT
8 63442-0D020-B ASA 1 Mouding Inhouse
NO.2
Moulding- Inhouse+
9 63444-0D020 PROTECTOR ROOF RACK FR LH ABS 1
Painting supplier
Bending,
Cutting, drilling. Inhouse+
10 63448-0D020-B BAR, ROOF CARRIER LH Aluminium 1
Buffing, supplier
painting
11 63472-0D010-D LEG, ROOF RACK FR LH Aluminium 1 Casting Supplier
12 63474-0D010-G LEG, ROOF RACK RR LH Aluminium 1 Casting Supplier
13 63487-0D020 CUSHION ROOF RACK LEG FR LH EPDM 1 Moulding Supplier
14 63489-0D020-A CUSHION ROOF RACK LEG RR LH EPDM 1 Moulding Supplier
19
Process Flow Chart
In house In house + supplier Supplier

MEASURE PHASE
21
Data Collection and Analysis
Child Part Availability for assembly APR -14
1200
1000
Number of Parts
800
600
400
200

Child Part Availability for assembly MAY -14
1200
1000
Number of Parts
800
600
400
200 Datenreihen1
Datenreihen2
0

Cumulative ChildPart avilability for April and May 2014
1200
Not meeting Plan
1000
800
Number of Parts
600
400
200
24
Bar Process Mapping

Bar Process First Pass Yield data
Painting
Rework 34%
Buffing Rework
21% Less FPY
26
ANALYSIS PHASE
27
Buffing
Buffing is the process done to finish the surface of aluminum

bars
Problems at buffing
Dents
Scratches
Over Buffing
Shape deformation
28
Rejection/Rework in Buffing Pareto
Pareto for buffing

50 100.00%
45 90.00%
40 80.00%
90% of the
35 rejection/rework is 70.00%
Number of parts
contributed by dents
30 60.00%
and scratches
25 50.00%
20 40.00%
15 30.00%
10 20.00%
5 10.00%
0 0.00%
Dents scratches Over buffing Shape deformation
Rew. Qty 44 18 5 1
Pareto Percentage 64.71% 91.18% 98.53% 100.00%
29
Types of rejection/ reworks in buffing
DENT DENT
SCRATCH
30
Cause and Effect diagram
MAN MACHINE
Improper air
pressure
Improper pad
selection
Low/high rpm
Skill Wrong
handling
Loose wheel
Dent and
scratches
Dust Non Burrs

particle uniform
scratch buffing
Handling Raw material

Handling of
High scratch problems
parts
pressure
METHOD MATERIAL Deep dents
in material
31
Dents and scratches:- Root cause-1
Deep dents in material
WHY Dents getting formed in bending process
Impression and rust marks from

WHY
supporting material in bending
transferred to bar
Supporting material
WHY Supporting bending material is soft and
corrosion prone
Supporting bend material needs to be

HOW? change
M.S.Ramaiah School of Advanced Studies 32

Dust particle scratch
WHY Scratches coming from dust particle
WHY Dust accumulation in work place
Buffing dust falling directly on table

WHY
WHY Operating table doesnt have provision

to collect falling dust
HOW? Proper operating and holding table to

be modified

Handling scratches
WHY Scratches while handling part
WHY Parts touching each other
WHY WHY
Parts touching each other in trolley Parts touching in bins
WHY No proper holding in trolley WHY No proper holding in bins
HOW?
Modified Bins and trolley to be introduced

Solutions -Proposal
Change support material in

bending process
Work table to be modified to

avoid scratches from table
Bins and trolley modification to

avoid handling scratches
35
Painting
Painting of the bar include two coats-
Primer coating and clear coating
Problems at buffing
Sagging
Dust / Seeds
Orange peel
Touch marks
Pin hole
Handling damage
Yarn
Dent
36
Rework in Painting Pareto
Painting Pareto
70 100.00%
90.00%
60
80.00%
78% of the rework is
50 contributed by sag and 70.00%
dust
Number of parts
60.00%
40
50.00%
30
40.00%
20 30.00%
20.00%
10
10.00%
0 0.00%
Handling
Sagging Dust / Seeds Orange peel Touch marks Pin hole Yarn Dent
damage
Rew. Qty 64 30 14 4 3 2 2 1
Pareto Percentage 53.33% 78.33% 90.00% 93.33% 95.83% 97.50% 99.17% 100.00%
37
Painting defect
Sagging
Dust/Seeds
38
Cause and Effect diagram
MAN MACHINE
Improper cleaning of
gun
Dust in work
place High air
Unclean PPE
pressure
Skill
Lack of
awareness Dust/
seeds &
Sagging
Hardener Raw
Temperatur material
percentage
e impurities
in paint
Non Dust in
Drooling
1 uniform aluminum Less paint
baking bar viscosity
Angle of Dust in
METHOD paint MATERIAL
primer paint
application
39
Seeds:- Root cause
Dust in primer paint
WHY Dust depositing after paint mixing
WHY Dust in working area WHY No closed lid put after

paint mixing
WHY Open paint booth
HOW?
Paint booth to be sealed and Closed lid painting to be put

Sagging:- Root cause
Drooling
WHY Clear coat settling down
WHY Drooling down due to gravity
Part height is more

WHY
WHY Part is vertically placed
HOW?
Horizontal painting to be introduced

Solutions -Proposal
Closed pot painting to avoid dust and

booth to be sealed
Change from vertical to

horizontal type painting
42
IMPROVE PHASE
43
Action 1 Change of support Plate
Current material -MS
-Hardness 120BH
-Poor corrosion resistance

Sl. Requirement Criteria

No.
1 Corrosion resistant Yes
2 Hardness >120BH
45
SS 304 material
selected for the bend
support material
46
Action 2 Buffing Table Change
Current material Buffing

in table
Sl. No Requirements
1 The part should be lifted from table
2 Part should not rotate while buffing
3 Easy to load and unload parts

Concept 1
Aluminum
bar holding
V- stand
for easy
rotation
Sl. Requirements
No
3 Easy to buff the part

Concept 2
Shape
modified for
aluminum
bar profile
Sl. Requirements
No

Concept 3
Handles for
easy rotation
Sl. Requirements
No

Implemented buffing table
Provision for
buffing M/c 1 2 3
holding
4

Action 3 Bins and Trolley change
Before condition
Bins
Trolley
Economic bin quantity

calculation
Avg. load that can be carried out

by Men = 5Kg
Approx weight of Bin= 1Kg
Weight of aluminum bar = 0.6Kg
Number of part to be carried in

Bin= 4Kg/0.6Kg
= 6.6653 6 number

Requirement Concept 1 Concept 2 Concept 3

Contact free storage YES YES YES
Bin Quality LOW HIGH HIGH
Handling POOR POOR GOOD

Implemented Bins
Additional cover to
protect from dust

Trolley: concept was developed such that bins can be

stored in trolley
Sl. No Requirements
1 100 set of material movement reqd. (
50LH+50RH)
2 Easy movement
3 Approx loading height: 180cm
4 Contact free storage

Trolley: concept was developed such that bins can be

stored in trolley
Sl. Requirements
No
1 100 set of material movement Carrying

reqd. ( 50LH+50RH) capacity
108Nos
2 Easy movement. Poor
3 Approx loading height:
4 Contact free storage Yes

Implemented Bins
LH/RH in
different side
for easy
accounting
Wheels for
movement

Solutions -Validation
Change support material in bending SS plate used

process
Work table to be modified to avoid scratches from V type fixture

table for holding
Bins and
Bins and trolley modification to avoid handling trolleys
scratches modified
Sl No Defect Solution proposals Trial done observation Judgemen

Further action Current status
Deep dents in Change support 100 sets material tried and no deep
material in bending OK Implemented
material dents observed in parts
process
Work table to be
1 Buffing Dust particle scratch modified to avoid 100 sets material tried and no dust
OK Implemented
scratches observed
scratches from table
Bins and trolley 1 trolley and 10 bins modified- found
Handling scratches OK Implemented
modification to avoid lower defect rate at tier-2
59
Action 4 Closed Pot painting
Before improvement
Paint is poured into the gun. Dust

formation and settling of metallic particle
is higher

Action 4 Closed Pot painting
Implemented Pressure pot
Closed pot avoid

dust particles Outlet
Inlet

Action 5 Horizontal painting
Before improvement
Sl. No Requirements
1 The part should be horizontally placed
2 Part should not rotate while painting

Sl. Requirements
No
1 The part should be
horizontally placed
2 Part should not rotate while
painting

Implemented Painting jig

Total number of Trial Parts painted (horizontally) = 200 Nos
Total number of rejection/rework : 3

No sag
Total number of parts with sag : 0 concern
observed
DFT (Dry film thickness) observed out of spec
Requirement : ED : 20-25 micron

Paint (Primer + Clear coat) : 50-55 micron
Observed : ED : 20-25 micron

Paint (Primer + Clear coat) : 95-115 micron
65
Paint DFT high
Paint DFT high
WHY More paint thickness
WHY Number of layer high
WHY Over coating
Operator not able to judge start and stop

WHY
of jig rotation
HOW?
Jig rotation to be controlled

Stopper provided to restrict

rotation
67
Solutions -Validation
Closed pot painting to avoid dust and Pressure pot

booth to be sealed type painting
system installed
Change from vertical to horizontal type painting Horizontal type

painting trial done
Paint DFT increased Jig modified
Closed pot painting to Tried with 1L closed pot container-

Dust in primer paint OK Implemented
avoid dust and booth out of 100set trial dust level defect
to be sealed clocked to 2% Jig modified to control the
1 Painting Change from vertical No sag issue in 100 sets trial in
rotation.Trial of 100set
Drooling to horizontal type horizontal type painting- Paint DFT Not OK Implemented
done -No sag- DFT
painting increased
thickness within spec.
68
Bar Process First Pass Yield data
FPY improved
98%
97%
69
CONTROL PHASE
70
SOP and check sheets
SOP s Revised
Revised document
Number:
Painting part monitoring MC/BE/01- Bending
check sheet MC/BF/01- Buffing
71
Cost for Equipments
Cost split up for Equipments

Sl no Item Qty Cost per Item (Rs.) Total cost (Rs.)
1 SS plates 1 500 500
2 Buffing table 1 5000 5000
3 Bins 1 1250 1250
4 Trolley 1 10000 10000
5 Painting Jig 1 150 150
16900
Supplier
6 Painting fixture 1 8000 8000
7 Paint booth modification 1 50000 50000
58000
72
Results
Roof Rail Delivery performance for Dec 2014 and Jan 2015
Sales Order Delivered In percentage (%)
15-Jan 1303 1440 111
14-Dec 1400 1550 111
Project Result
120%
100%
Delivery percentage
80%
60%
40%
20%
0%
Apr& May 2014 Target Dec 14 and Jan 15
Datenreihen1 70% 100% 111%
73
Project Schedule Vs Actual
Week numbers
Activity 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Project P
presenation A
P
Literature review A
Importance of the P
problem A
Data collection for P
the current state A
Root cause P
analysis A
P
Solution proposal A
Interim P
presentation A
Action plan for P

implementation A
Implementation P
of action A
Monitoring and P
standardisation A
Final project P
review A
P
Thesis draft A
Final project P
presentation A
Final dissertation
P
and thesis
submission A
74
Conclusion
The project achieved the targeted delivery
performance
FPY of Buffing and painting station was
improved from 77% to 98% and 61% to 97%
respectively.
Painting rejection reduced from 5% to 1%
DMAIC approach helped to solve the problem
Recommendations of Future Work
LAB value for colour data study and study on parameters

affecting the same
Alternate process for Buffing of aluminum
75
Reference
[1] http://www.namosteel.co.in/stainless-steel-
grades.html
[2]
http://www.suncorstainless.com/sites/default/files/Stai
nless%20Steel%20Chart%20-%20General.jpg
[3] http://www.azom.com/article.aspx?ArticleID=965

Benefits of the work
Will it result into a publication? Yes
Will it result into a product? No
Will it be a solution to an existing problem of an industry? Yes
Is it pursued for academic interest? Yes
77

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Final Project Presentation

Delivery Performance Improvement of an

Academic Guide : Industrial Guide :

To improve delivery performance of roof rail

To carryout literature survey on delivery performance, painting,

The details of existing process flow collected from process flow

Gemba study carried out to understand the process requirements and

Appropriate solution for each problems found

Validation of the implemented solution and standardization done

Horizontal deployment on other running roof rail projects ( Ford

Team Concepts Pvt. Ltd.

M.S.Ramaiah School of Advanced Studies

Factor model of manufacturing difficulties , First pass

Ranjan Raj Urs S, Dr. B.P.Mahesh, Sandesh S

De Mast J and Lokkerbol J.

DMAIC is a systematic six-sigma project management practice inspired by Deming's

Monthly OEM Sales in %

860A roof rail Sale order Vs Delivery

Roof Rail Delivery performance for April and May 2014

Business Loss Of Rs.27 Lakhs

M.S.Ramaiah School of Advanced Studies

M.S.Ramaiah School of Advanced Studies

M.S.Ramaiah School of Advanced Studies

M.S.Ramaiah School of Advanced Studies

M.S.Ramaiah School of Advanced Studies

Buffing is the process done to finish the surface of aluminum

Pareto for buffing

Dust Non Burrs

Handling Raw material

Deep dents in material

WHY Dents getting formed in bending process

Impression and rust marks from

Supporting bend material needs to be

M.S.Ramaiah School of Advanced Studies 32

Dust particle scratch

WHY Scratches coming from dust particle

WHY Dust accumulation in work place

Buffing dust falling directly on table

WHY Operating table doesnt have provision

HOW? Proper operating and holding table to

M.S.Ramaiah School of Advanced Studies 33

WHY Scratches while handling part

WHY Parts touching each other

WHY No proper holding in trolley WHY No proper holding in bins

M.S.Ramaiah School of Advanced Studies 34

Change support material in

Work table to be modified to

Bins and trolley modification to

Dust in primer paint

WHY Dust depositing after paint mixing

WHY Dust in working area WHY No closed lid put after

WHY Open paint booth

M.S.Ramaiah School of Advanced Studies 40

WHY Clear coat settling down

WHY Drooling down due to gravity

Part height is more

WHY Part is vertically placed

M.S.Ramaiah School of Advanced Studies 41

Closed pot painting to avoid dust and

Change from vertical to

Current material -MS

M.S.Ramaiah School of Advanced Studies