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Hinduja Foundries Ltd,

Sriperumbudur

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Hinduja Group

Hinduja Group is owned by Mr. Srichand P


Hinduja and his brothers Mr. Gopichand P
Hinduja, Mr. Prakash P Hinduja, Mr. Ashok P
Hinduja, more simply known as Hinduja brothers
for short. Hinduja Group was found in 1914 by
Mr. Parmanand Deepchand Hinduja, Initially
operating from Mumbai-India and setting up first
international operation in Iran in 1919. Hinduja
group are in the fields of Automotive,financial
services, its,Oil and gas, media and telecom.

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The Hinduja Group
incorporates
Ashok Leyland IDL Specialty Chemicals Ltd
Hinduja Foundries Ltd Hinduja Realty Ventures Ltd
Hinduja Bank (Switzerland) Ltd Ashok Leyland Wind Energy Ltd
Hinduja Tech Limited (formerly Defiance
IndusInd Bank
Technologies Limited)
Hinduja Leyland Finance Ltd Hinduja Group India Limited
Hinduja Global Solution Ltd (formerly P D Hinduja National Hospital and Medical
named HTMT Global Solutions) Research Centre
Hinduja Ventures Ltd Hinduja Healthcare Ltd
Gulf Oil Corporation Ltd KPB Hinduja College of Commerce
Gulf Oil Middle East Ltd Houghton International
Hinduja National Power Corporation Ltd Albonair GmbH, Germany

HindusInd Media and Communications Ltd

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Introduction to HFL
Hinduja foundries limited (HFL) have two plants as
mentioned below,
HFL Ennore
HFL SPU (Sriperumpudur unit)
History of Hinduja foundries (Previously Ennore Foundries)
are as mentioned below,
Initially promoted by British Leyland as Ennore Foundries
Limited (EFL)
EFL became a member of HINDUJA GROUP in 1987.
The company name changed from Ennore Foundries
Limited (EFL) to Hinduja Foundries Limited (HFL) from 14-
Feb-08 onwards.
Set up as a Greenfield Venture with a vision of becoming
a world leader in Foundries.

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Mission

To establish and continually improve


technology and processes in achieving global
standards.
To enhance the overall potential of our human
resources through training and development.
To establish and continually improve the
supplier performance to global standards.

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Scope

MANUFACTURE OF GREY IRON CASTINGS


AND MACHINING OF CASTINGS

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Foundry rejection of
Scabbing reduction in JCB
cylinder block (HF 131)

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Problem Description

Foundry Rejection of JCB block is 10.5 %


(Jun16 to Oct16) and bring the block under
Top 5 Rejection. This leads to high amount of
companys money loss and also affecting
dispatch target causing customer
dissatisfaction. Among 10.5%, the Scabbing
defect contributing 2 %.

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Project Team

Roles &
# Name Function
Responsibility
Sponsor Div.
1. D.Sathyanathan Quality
Manager
2. V.Giri Project Leader Quality

3. R.Gopinath GET QMS Quality

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Tools Used
Check sheet
Histogram
Pareto chart
Control charts
Cause-and-effect diagram
Why - Why Analysis

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Time Chart

Timelines / Nov Nov Nov Dec Dec Dec Dec Jan Jan Jan Jan Feb Feb Feb

Phase W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14

P
Problem
Identification A

P
Observation
A

P
Analysis
A

P
Action
A

P
Check
A

P
Standardisation
A

P
Conclusion
A
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Process Flow

Core Core
Raw material Core making Core making Core Drying
assembly painting

Melting
Cores Mould
Knock out & Mold closing Sand mix
setting making
pouring

Secondary
Decoring Shot blasting MF 1 MF 2 Painting
shot blasting

Final
Despatch Packing
inspection

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Problem
Observation

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Check Sheet for Data
Collection

Check Sheet

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Histogram

Rejection Quantity for Scabbing


50
45 46
45
40 Quantity
Rejection
35
30
25 26 26 Rejection
24
20
15
10
5
0
Jun July Aug Sep Oct
Month

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Scabbing Rejection trend from
Jun16 to Oct16

Scabbing Rejection trend from Jun16 to Oct16


2.0 1.9
1.8 1.6
1.6 1.5
1.4
% of Rejection 1.4
1.2
1.0
1.0
0.8
0.6
0.4
0.2
0.0
Jun'16 July'16 Aug'16 Sep'16 Oct'16

Month

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Pareto for Jun16 to Oct16

300 275 120%


98% 99% 99% 100%100%100%100% 100%100%
236 96% 97% 98%
250 89%
93% 95% 100%
216 85%
77%
200
Cumulative 80%
67%
159
150 55% 141 60%
38% 98
100 40%
21% 58
47
50 26 20%
16 13 13 10 9
4 2 2 1 1 1 1
0 0%

Defects Defects
Cummulative %

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Defects as-is Photos

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Defects as-is Photos

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Defects as-is Photos

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P Chart for Scabbing (Jun16
to Oct16)
P Chart of Scabbing
1
1
0.4 1 1
1
1
1
0.3
1
1 1
Proportion

1 1
1 1
1
0.2 1 1 1
1 1
UCL=0.1508

0.1 _
P=0.0767

0.0 1 1 1 1 LCL=0.0026
1 1 1 1 1

Date
Tests are performed with unequal sample sizes.

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Fish Bone Diagram

Equipmen
Man Machine
t

Squeeze pressure
Due to interrupted Mould hardness
high (mould)
pouring Tester not

Scabbing
validated

Unskilled labour

More radiation at sump area


Low Moisture
Low GCS/High GCS
High Moisture
High pouring Temp
Mould hardness high
Less addition of new sand Poor quality of
High pouring time Sand Additives
Ineffective venting
Sand temp high

Method Material

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Cause & Effect matrix
Importance rating 1-10
S.No KPOVs Scabbing Rating Total %
1 Squeeze pressure high (mould) 3 3 30 5%

2 High pouring Temp 9 10 90 16%

3 High Moisture 3 3 30 5%

4 High pouring time 9 10 90 16%

5 Sand temp high 3 3 30 5%

6 Unskilled labour 3 3 30 5%
Process
Steps & 7 Due to interrupted pouring 3 3 30 5%
Key 8 Low Moisture 3 3 30 5%
Process
Input 9 Low GCS/High GCS 4 4 40 7%
Variables
10 Mould hardness high 2 2 20 3%

11 Less addition of new sand 9 10 90 16%

12 Ineffective venting 2 2 20 3%

13 Mould hardness Tester not validated 3 3 30 5%

14 Poor quality of Sand Additives 2 2 20 3%

15 More radiation at sump area 9 10 90 16%

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Validation of potential
root cause
Standard/ Significant
Sl.No Potential Root Cause Check Point Validation
Specification Yes / No
Squeeze pressure high Verified the set pressure and actual no
1 KW MOULDING As per JES/CP No
(mould) variation observed.
2 High pouring Temp POURING As per JES/CP Checked 30 boxes no deviation observed No
Moisture checked for 15 batches all are
3 High Moisture SAND PLANT As per JES/CP No
within specifications
Simulation recommended pouring time
4 High pouring time POURING MAGMA Yes
22-24 sec, Actual : 24-28 sec
Sand temperature checked for 30 batches
5 Sand temp high SAND PLANT As per JES/CP No
and no variation observed
Moisture checked for 15 batches all are
6 Low Moisture SAND PLANT As per CP No
within specifications
GCS checked for 15 batches all are within
7 Low/high GCS SAND LAB As per CP No
specifications
Mould hardness verified for 30 boxes all
8 Mould hardness high MOULDING As per SOP No
are with in spec
9 Ineffective venting MOULDING As per STD Venting are as per piercing drawing No
Mould hardness Tester not Mould hardness tester are calibrated and
10 MOULDING As per STD No
validated validated
Poor quality of Sand Quality of incoming additives verified no
11 LAB As per Design No
Additives deviation
Less addition of new New sand addition maintained min side
12 LAB As spec. Yes
sand of the spec.
More radiation at sump
13 Mould As per Standard Pouring bush overlapping on sump area Yes
area

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Why-Why Analysis
Why-Why Analysis for Less addition of Why-Why Analysis for High
new sand pouring time

Less addition of New sand High pouring time


Why Why

New sand addition maintained More turbulence and


Why lower side of spec. Why velocity

Due to core sand infiltration In Adequate gating system


Why varying on product mix Why

Gating not reviewed


Why Why through magma simulation

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Why-Why Analysis
Why-Why Analysis for More Radiation at Sump
Area

More radiation at sump area


Why

Pouring bush overlapping the


Why sump area.

Each cavity having each down


Why Sprue

Designed stage it made


Why

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Before /After Evidence for
Sand Addition
Before After

140 mm

Sprue Cutter was in 120 mm leads to Width of Sprue cutter increased to 140
High Pouring time (24-28 Sec) mm to reduce pouring time (22-24 Sec)
Cut off 09-11-16
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Before /After Evidence for
Sand Addition
Before After

Before Modification After Modification


Corrective Action:

Down Sprue to be made as single and pouring bush to be designed accordingly to


avoid overlapping of bush metal at sump area

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Before /After Evidence for
Sand Addition
Before After

Cut off 09-11-16


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After Corrective Action:
P Chart for Scabbing (Nov16 to
Feb17)
P Chart of Scabbing
0.09 1
1
0.08 1
0.07

0.06 1 1
Proportion

0.05 UCL=0.05020

0.04

0.03
_
0.02
P=0.01757
0.01

0.00 LCL=0

Date
Tests are performed with unequal sample sizes.

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After Corrective Action
Scabbing Rejection trend from Nov'16
to Feb'17
Scabbing Rejection trend from Nov'16 to Feb'17
0.4
0.3
0.3
Changes in
0.3 Raw Material
% of Rejection
0.2
0.2

0.2 0.1
0.1
0.1

0.1

0.0
Nov'16 Dec'16 Jan'17 Feb'17

Month

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Full Scale Implementation
Plan & Status

RYG
Responsibi
# Counter Measure Pilot area Stat
lity
us
New sand addition increased from
1 Sand Lab DVG/KALAI
80 Kgs to 120 Kgs
Design/moldi
3 Pouring Sprue cutter change DSA/SAM
ng

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Check Summary

RYG
# Root Cause Counter Measures taken Statu
s
Less New sand New sand increased from 80 Kgs 120
1
Addition Kgs / batch
Excess pouring
2 Pouring Sprue cutter changed
Time

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PFMEA - Updated

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Control Plan - Updated

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P Chart of Scabbing- After
improvement

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Conclusion

Scabbing Rejection trend from Jun16 to Feb17


2.0 1.9
1.8 1.6
1.6 1.5
1.4
1.4
% of Rejection
1.2
1.0
1.0 After
Corrective
0.8 Action
Changes in
0.6
Raw Material
0.4
0.3 0.1
0.2
0.2 0.1
0.0
Jun'16 July'16 Aug'16 Sep'16 Oct'16 Nov'16 Dec'16 Jan'17 Feb'17
Month

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Thank You
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