Training Report

KAIZEN
Event On
To Ramp up PDI Production from 70 / Shift to 100 /
Shift
www.ebz-gmbh.de
At TCF 1C Shop
Uttarakhand
Responsibility : Ranjit Singh
FROM 18.01.2013 to 25.01.2013
KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.
SUPER ACE & VENTURE Project

TATA MOTORS LTD. Pantnagar
Team Members Participation
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Team Members Participation
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91.1 %

Reason for selecting the theme To Ramp up PDI Production from 70 to 100 / Shift
1 .AS WE HAD ACHIEVED ROLL OUT OF 100 / SHIFT THERE IS PROBLEM IN CLEARENCE AT PDI 2.30 % output loss due to Rework
3. 30 Mins to 120 Mins time is required for Rework of BIW, Trim, UB & Mech Line.
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REDUCE DEFECTS
Ramp up PDI Output

Activity Plan
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Objective, Target & Deliverables

OBJECTIVE
- To Eliminate top 5 defects at PDI.
To modify layout of Shower & PDI for better retrieval of parts.
- To improve material feeding system.
- To improve rejection clearance system.
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TARGET & DELIVERABLES :

-Output / Shift to be increased from 70 / shift to 100 / shift. -To reduce DPV from 10 to 5. -Design new count free & easily retrieved trolleys . -Educate and trained supplier / TML people. -100 % dedicated Location along with Identification
KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift. SUPER ACE & VENTURE Project
Problem Solving Approach
DATA COLLECTION
KAIZEN SUSTENANCE
PLAN
ACT DATA INTERPRETATION KAIZEN VALIDATION
DO
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CHECK
PROBLEM DEFINITION
KAIZEN IMPLEMENTATION
4M Analysis
KAIZEN IDENTIFICATION

Data Collection & Interpretation
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Pictorial View of Defects
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Problem Definition 5W1H
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ROOF LAMP GAP NG
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ANALYSIS
Roof lamp mtg bkt required 21 mm from roof but in actual its coming 26-27 mm (variation of 5-6 mm). Reason - No fixture for roof spotting.
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Name of employee: Operation/Machine
Ticket No:
Shop/Area: Tcf1c
Line/Station
Date:
Problem
Gap observed after fitment of Roof liner & roof lamp
Measure Taken
Roofliner foam thickness increased to 5 mm to absorb variation
Results
Result OK both at TR 30 & PDI. Fixture for roof spoting is in process at BIW
Roof lamp fitment
Before Kaizen
After Kaizen
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Door to Weather Strip Gap NG
ANALYSIS
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Gap observed between weathger strip & door pad. Weather strip lip NG. Require = 10 mm & actual = 8 mm. On the basis of 4M analysis we found that Weather strip is NG On the basis of 4M we found that in Machine Die issue, Pressing NG on LH side resulting more gap on one side.
Ticket No:
Shop/Area: Tcf1c
Line/Station:
Date:
Problem
Door pad to weather strip gap observed
Measure Taken
Length of lip in creased from 8 mm to 10 mm -- Tejpal
Results
No gap observed at PDI
Weather strip fitment
Defect Zero
Before Kaizen
After Kaizen
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Load Body hook / hinge fouling
ANALYSIS
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Hook Fouling 1. Uneven gap between tailgate/ side panel wrt Load body floor 2. Front panel flushness NG wrt side panel 3. Load body hook setting done on trim line in TCF, at that time, vehicle body is on conveyor. After drive load body adjust itself results in small hook fouling at PDI. Hinge fouling 1. Uneven gap between tailgate / side panel wrt Load body floor. 2. Waviness in skirt panel. 3. Hinge slot not OK.
Ticket No:
Shop/Area: Tcf1c
Line/Station:
Date:
Problem
Load body hook fouling 1.
2.
Measure Taken
Stud length decreased by 15 mm. Triangle jig made at supplier end to control flushness of front panel. 100 % inspection of load body hook at shower by BIW.
Results
Even gap achieved PDI defect reduced
Load body, toggle clamp fitment
3.
Before Kaizen
After Kaizen
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Ticket No:
Shop/Area: Tcf1c
Line/Station:
Date:
Problem
Load body hinge fouling
1. 2.
3. 4.
Measure Taken
Stud length decreased by 15 mm. Child part added in skirt panel to avoid waviness. Hinge slot shift by 2 mm New type of hinge implemented. Mr. Dilip Singh (SQIG)
Results
Result OK but activities in process. Defect decreased at PDI
Load body fitment
Before Kaizen
After Kaizen
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Bumper gap & flushness NG
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ANALYSIS
Flushness of bumper wrt side bonnet not ok. Bumper not locked properly with side bonnet.
Ticket No:
Shop/Area: Tcf1c
Line/Station:
Date:
Problem
Gap & flushness between bumper & side bonnet
Measure Taken
Bumper mtg stopper bkt shifted by 2. 5 mm in Z direction. Checking unit added at supplier end for bumper mtg bkt in frame. Mr. Ritesh Chattoo (SQIG)
Results
Locking of bumper & side bonnet improved results in better gap & flushness.
Bumper fitment
Before Kaizen
After Kaizen
Bkt shifted 2.5mm in Z direction
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Seat toggle clamp centering not ok
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ANALYSIS
Seat shifts towards left of the vehicle during tightening of seat mounting bolts. On the basis of 4M analysis we found that Method is NG.
Ticket No:
Shop/Area: Tcf1c
Line/Station:
Date:
Problem
Seat toggle clamp offset wrt seat lock
Measure Taken
Process changed. First operator hand tight seat mtg bolt then he will lock seat toggle clamp. Afterwards he will tight with gun
Results
. Result coming OK but still in process
Seat Fitment
Before Kaizen
After Kaizen
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Ticket No:
Shop/Area: Tcf1c
Line/Station:
Date:
Problem
Rack placed and lots of covers kept at PDI
Measure Taken
Dedicated trolley made for PVC covers
Results
. 2S maintained
PVC Cover fitment
Before Kaizen
After Kaizen
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Ticket No:
Shop/Area: Tcf1c
Line/StationDate:
Problem
Rack placed and lots of covers kept at PDI
Measure Taken
Dedicated trolley for side console placed at PDI and rack eliminated
Results
. 2S maintained
Side console fitment
Before Kaizen
After Kaizen
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Ticket No:
Shop/Area: Tcf1c
Line/Station:
Date:
Problem
Wheel rim cover kept in cartoon boxes
Measure Taken
Dedicated trolley made for keeping wheel rim covers
Results
. 2S maintained
Wheel rim cover fitment
Before Kaizen
After Kaizen
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Vehicle Flow in Shower & PDI - Before

T/U Line PDI Line Shower
TR Repair
T/U Repair
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Front Panel, Bumper fitment & PVC cover fitment, Door setting gap & flushness, Side Console, Child parts DT

Vehicle Flow in Shower & PDI - After

T/U Line PDI Line Door Setting gap & flushness
Shower
TR Repair
T/U Repair
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Side Console & Child Parts
Front Panel, Bumper fitment & PVC cover fitment DT

Kaizen Newspaper
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Kaizen Even Results

10 9 8 7 6 5 10
140 120
7 Before Current Target
100 80 60 40 20 0 Avg. PDI Nov'12 Dec'12 Jan'13
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4 3 2 1 0 DPV

WAY FORWARD
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KAIZEN

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

Team Members Participation

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

Team Members Participation

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

Ramp up PDI Output

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

Objective, Target & Deliverables

To modify layout of Shower & PDI for better retrieval of parts.

- To improve material feeding system.

- To improve rejection clearance system.

TARGET & DELIVERABLES :

Problem Solving Approach

ACT DATA INTERPRETATION KAIZEN VALIDATION

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

Data Collection & Interpretation

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

Pictorial View of Defects

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

Problem Definition 5W1H

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

ROOF LAMP GAP NG

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

Name of employee: Operation/Machine

Roof lamp fitment

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

Door to Weather Strip Gap NG

Name of employee: Operation/Machine

Weather strip fitment

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

Load Body hook / hinge fouling

Name of employee: Operation/Machine

Load body, toggle clamp fitment

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

Name of employee: Operation/Machine

Load body fitment

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

Bumper gap & flushness NG

Name of employee: Operation/Machine

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

Seat toggle clamp centering not ok

Name of employee: Operation/Machine

KPO/UKE346/Ranjit Singh To Ramp up PDI production from 70 / Shift to 100 / Shift.

SUPER ACE & VENTURE Project

Name of employee: Operation/Machine

PVC Cover fitment