Six Sigma Project Final

Q-Star Advance Project 1© Copyright, Confidential, Tata Motors Ltd
Lean Six Sigma ProjectLean Six Sigma Project
onon
To eliminate sub frame mtg. holeTo eliminate sub frame mtg. hole
mismatch with frame nut in TCFmismatch with frame nut in TCF
Submitted by Pradeep Tiwari Ticket No. 602551
Deptt. Biw – 1C Program /Module SIX SIGMA

Project Selection Check ListProject Selection Check List
No. Criteria Yes No
1 Project is a strategic priority, aligned with a Big Y √
2 There is no overlap with other GB / BB projects √
3 Scope of the project is under the area of my influence √
4 Project scope is limited to only one product / one type of defect √
5 It is related to repetitive problem (chronic, not sporadic) √
6 Team cannot solve it by engineering judgment. √
7 A significant ROI expectation has been established √
8 Right vertical & horizontal team members are available √
9 Several team members are top talent & innovative thinkers √
10 Management is willing to commit serious resources to solutions √
11 Project is capable of completion within 2~4 months √
12 Capable team leader and champion assigned √

Business Case / Justification for Project Selection Opportunity Statement
The project supports DRR & DRL improvement, COPQ
Reduction and line stoppage reduction of TCF Shop.
Pain : Product is getting reworked at TCF and extra 2
manpower deployed it’s repairing. Majorly produced vehicle
are having same defect.
Quantification : DPV of product is 3.5 & Daily 2 manpower
are required for reworking this particular defect.
Impact of pain in Rs. (or soft) : Rs.20.9 lack p.a. is paid
for this rework.
Goal statement Project scope
Metric Current level Target The scope of the project begins at the time of cab being
received at TCF from Paint Shop until the vehicle is fully
assembled and made ready for dispatch.
Sub frame rework in
Super Ace / Venture
70-75% rework Zero Rework
DPV- 3.5 DPV-1.0
Project plan Team
Phase Start End Role Name Dept.
Sponsor Mr. S. Waghchaure BIW – 1C
Define 01/09/14 12/10/14 Champion / Guide Mr. Mohanish Q O
Measure 13/10/14 24/10/14 Leader Pradeep Tiwari BIW – 1C
Analyze 02/11/14 29/11/14 Member Ganga Singh BIW – 1C
Improve 30/11/14 31/12/14 Member Vikrant TCF – 1C
Control 01/01/15 30/01/15 Member Pankaj Adhikari BIW – 1C
Member Ritesh Chattoo SQIG
Project CharterProject Charter

•The issue of Sub frame rework in DRR TCF 1C was taken up as Six Sigma project and the
reason is evident from the above table. Since there are multiple and complex causes with no
proper solution, I have, with the support of the management, decided to use DMAIC approach
to solve the problem.
Why Sub frame fitment problem as a Six sigma project?

DEFINE
What is the pain?

DEFINE PHASE
Problem Identification & JustificationProblem Identification & Justification
(KPM Tree – Business Goal)(KPM Tree – Business Goal)
PLANT QUALITY PERFORMANCE IMPROVEMENTPLANT QUALITY PERFORMANCE IMPROVEMENTPLANT QUALITY PERFORMANCE IMPROVEMENTPLANT QUALITY PERFORMANCE IMPROVEMENT
CPACPA
IMPROVEMENTIMPROVEMENT
CPACPA
REDUCE CUSTOMERREDUCE CUSTOMER
(TCF) COMPLAINS(TCF) COMPLAINS
REDUCE CUSTOMERREDUCE CUSTOMER
(TCF) COMPLAINS(TCF) COMPLAINS
Big Y
(Metric)
Small y’s
(Key drivers)
Vital X’s
DIRECT RUN LOSSDIRECT RUN LOSS
DIRECT RUN LOSSDIRECT RUN LOSS
DIRECT RUN RATEDIRECT RUN RATE
DIRECT RUN RATEDIRECT RUN RATE
SHOP QUALITY PERFORMANCE IMPROVEMENTSHOP QUALITY PERFORMANCE IMPROVEMENTSHOP QUALITY PERFORMANCE IMPROVEMENTSHOP QUALITY PERFORMANCE IMPROVEMENT
Engine coverEngine cover
to consoleto console
gap N.G.gap N.G.
Engine coverEngine cover
to consoleto console
gap N.G.gap N.G.
DoorDoor
glassglass
HardHard
DoorDoor
glassglass
HardHard
L/B tail gateL/B tail gate
panel foulpanel foul
L/B tail gateL/B tail gate
panel foulpanel foul
Sub frame mtg.Sub frame mtg.
hole mismatchhole mismatch
Sub frame mtg.Sub frame mtg.
hole mismatchhole mismatch
Tail gateTail gate
to sideto side
panel gappanel gap
N.G.N.G.
Tail gateTail gate
to sideto side
panel gappanel gap
N.G.N.G.

Problem Identification & Justification(Pareto & Trend Chart)Problem Identification & Justification(Pareto & Trend Chart)
DEFINE PHASE

Assy. Sub frame with frame
Two Center Stud (LH/ RH)
used to mount the engine carrying
sub frame
Mounting of remaining 8 studs
and 6 bolts was done after the
engine stuffing process.

DEFINITION OF PROBLEM
Frame & Sub frame hole
mismatch with jack mount
stud position.
Side Bkt Nut offset with Sub
frame
Mismatch with front stud
Sub frame hole mismatch
with Frame Inner BKT
FRAME
SUB FRAME

TCF Process
Engine assy. With Sub
Frame.
Sub frame fastener
torquing.
Comp. Assy sub fame from
BIW
Assy. Comp. frame
from BIW end
Assy. Engine in TCF with
Sub Frame
Matching of sub frame &
frame in TCF

Assy comp. frame S.Ace
Side Mtg Bkt
Front Stud
Mtg Bkt
Jack Mtg Bkt
Centre Stud
Mtg Bkt
Total No. of
Sub frame mtg
Nuts 16 No.

Finished Assy. Sub frame
Rack & Pinion
Mtg Bkt
Side Mtg Bolt
Front Stud
Mtg Hole
Jack Mtg
Hole
Rack & Pinion
Mtg Bkt
Side Mtg
Bolt
Centre Stud
Mtg Hole
Total No. of mtg.
10 stud + 6 Bolt

Matching of Sub frame with Frame .
Assy
SubFrame
Assy
Frame

CTQ & CTP Drill-DownCTQ & CTP Drill-Down
Critical to
Quality
Critical
customer
requirement
Customer
issues
Voice of
customer
DRL to be
improved
Proper
tightening of
Bolt & Stud as
per specification
Sub frame &
Frame mismatch
issues should be
avoided.
Sub frame
rework issues
are very high in
DRL.
Voice of
business
Business
issues
Critical
business
requirement
Critical for
processes
High customer
dissatisfaction
Issues in finished
vehicles to be
eliminated
No mismatch
issues
DPV 3.5 TO 1.0
Tips :
1. Voice of customer and voice of business to be prioritized to those which are related to project objective
2. Use VOB or VOC or both depending on the project objectives
3. CTQ / CTP should be in NUT form (Name of the parameter, Unit of Measure, Target value)
DEFINE PHASE

What
What is the problem? Frame nut mismatch with Sub frame mtg hole
What has the problem? (part no,
Lot no, etc.)
Frame
What is the impact of the
problem? (money, people, time,
etc.)
High Rework impacts on time , Less Productivity, High DRL, Low Employee Moral, High Cost & Unsafe work.
Where
Where is problem located on
Product/Part?
Frame & Sub frame
Where does the problem occur
in the process?
TCF Under Body Line St - 6
Where was the problem
observed in the process?
After Engine Stuffing with frame
When
When was the problem first
noticed?
From the first day of production
When has it been noticed since? Regular Basis
Who
Who is affected by the problem? Line operator
Who first observed the problem? Line Operator
To whom was the problem
reported?
Production / BIW
How
How much is the problem / impact
of problem?
Line stoppages in TCF
How is the problem being
rectified / corrected?
Rework by grinding & tapping.
Problem Explanation (4W-1H)Problem Explanation (4W-1H)
DEFINE PHASE

SIPOC DiagramSIPOC Diagram
Engine
Stuffing
Engine
Stuffing
Sub-processes
DEFINE PHASE
Suppliers Inputs
BIW Sub Frame
Panse Frame
Engine Shop Engine Assy
TCF Engine Assy with
Sub Frame
Outputs Customers
Finished Vehicle Final PDI
Assy Sub Frame
Engine Assy On
Sub Frame
Body on Frame Engine Stuffing

Top Down ChartTop Down Chart
DEFINE PHASE
Step-1 Step-2 Step-3 Step-4
Assy. Sub frame Engine Assy On Sub
Frame
Body on Frame Engine Stuffing
Bush welding Assy. Side mbr LH
& RH
Sub frame, Spring Coil & Lower Link
loading on fixture
Frame comes from Panse
Body comes from U/B S.No-4 and Sub
frame with engine comes.
Rack & Pinion ,FRT X mbr , RR X
mbr weld
Rack & Pinion , sub frame bkt & Power
steering bottle fitment
Assy U/ B weld with frame
Lift up sub frame up to frame height
and sub frame hole match with frame
nuts
SPM drilling (bush hole enlarge) FRT axle strut fitment Side wall , roof weld with frame
Qualifying stud & bolt on sub frame
mtg. nuts
Final inspection Engine loading & fitment on sub frame
Door , L/B fitment & final
inspection
Torqueing done as per spec.
Send to Badve for powder
coating
Inspection engine with sub frame Comp. BIW send to paint shop
Sent to TCF Engine loading
Body comes Mech. Line from
Paint shop
Engine with sub frame unload on dolly Body comes U/B S. No. -5
Send dolly to U/B S. N.- 5
Activities

Operational Definition
Sl. No. Performance Indicator (Y) Operational Definition
Y1
Sub frame hole not centric with
frame M10 nuts
Any mismatch of sub frame hole with frame nut defect
which is visible to the bare. Mismatching defect may be
one or more in number in a single Body but considered
to be one single defective product.
Sl. No. Process / input Indicator (X) Operational Definition
X1 Assy. Sub frame welding Sub frame child part welding by MAG welding.
X2
Complete BIW
To weld cabin with frame called BIW.
X3
Engine assy. On the S.F.
To assemble Engine on the sub frame.
X4
Engine stuffing When Engine Assembled sub frame matching with BIW
frame that’s called engine stuffing operation.
X5
Torqueing
Tighten nuts as per spec. Called torqueing.
X6
Operator Name of the operator who matching sub frame with
BIW frame.
X7
X8

PROCESS WALKTHROUGH (3G)
Final
inspection
Sub frame
Sub frame
stage -2
Sub frame
stage -1
Send to Badve
for ED & paint
Engine
Stuffing
U/B ST. N. -6
Mismatch
Problem occurs
here
Assy. Frame
comes BIW -1c
from supplier
Comp. BIW
with frame
Send to
Paint
shop
Dropping TCF –
1C Mech. line
U/B ST.
N. -5
Sub frame
comes TCF
from Badve
Engine Sub
Assy.-1,2
&3
Engine loading
on Sub frame
St. N. -4
Engine with sub
frame inspection &
send to U/ B line
Engine with sub
frame loading
on Dolly
U/B ST. N. -7
U/B ST. N. -11
Torqueing
U/B ST. N. –
1, 2 ,3 & 4

Area
What Standard
says?
What is Observed? Photo / Sketch
Potential Quick-
win opportunities
TCF 1C
U/B Line
Stage -6
Proper
matching of
sub frame hole
with Frame
mtg. nuts
Sub frame hole
mismatch with frame
mtg. nuts.
(Sub frame mtg. hole
not centric with
frame nuts)
1.Sub frame mtg.
hole (FRT STUD
HOLE) cutting and
nut tapping.
2. Frame old nut
replace with new
nut weld.
Process Walk Through (3G)Process Walk Through (3G)
DEFINE PHASE

Quick-Win Selection & ImplementationQuick-Win Selection & Implementation
DEFINE PHASE

24
FRA
ME
NO.
5949
FRA
ME
NO.
5950
FRAM
E
NO.
5951
FRAM
E
NO.
5952
FRA
ME
NO.
5953
FRAM
E
NO.
5954
FRAM
E
NO.
5955
FRAM
E
NO.
5956
FRAM
E
NO.
5957
FRA
ME
NO.
5958
RESULT OK NOT
OK
OK OK OK OK NOT
OK
OK OK NOT
OK
STUD IN A TAPPER
WITH FRAME FRA
ME
NO.
5959
FRA
ME
NO.
5960
FRAM
E
NO.
5961
FRAM
E
NO.
5962
FRA
ME
NO.
5963
FRAM
E
NO.
5964
FRAM
E
NO.
5966
FRAM
E
NO.
5967
FRAM
E
NO.
5968
FRA
ME
NO.
5959
RESULT OK OK OK OK OK OK NOT
OK
OK OK OK

DEFINE PHASE
Area
What Standard
says?
What is Observed? Photo / Sketch
Potential Quick-win
opportunities
TCF U/B
STUD SHOULD BE
QUALIFING
PERPENDICULAR.
Nut welded with a taper due
to no standard Welding
process. Above
PROJECTION WELDING
STARTED IN PLACE OF MAG
WELDING.
BeforeBefore AfterAfter
Nut weld by
MAG welding
Nut weld by
Projection
weldingStud not perpendicular

MEASURE
What is the root cause?

27
Sub frame
mtg. Hole
mismatch
with frame in
TCF
Unskilled
manpower
Behavior
Irregular
operator
Lack of
awareness
Preventive maintenance
of sub frame fixture
Process
Sequence
not ok
WIS not
followed
Tightening
sequence not
ok
Frame Dim. Not ok
Sub frame Dim.
Not okNut tapered on
frame
Fixture Resting
block condition
MachineMan
Material Method
CAUSE AND EFFECT DIAGRAM
Environment
Improper Visibility
Improper Space

Prioritization of CausesPrioritization of Causes
Mismatch
10
1- Nut taper welded in frame 3 3
2- Sub frame dim. N.G. 9 9
3- Frame DIM. N.G> 9 9
4- Low tolerance of sub frame hole 9 9
5- Wrong vehicle resting pad 3 3
6- Preventive maintenance of fixture 3 3
7- Fixture clamp & block condition 3 0
8- Unskill manpower 0 0
9- Irregular operator 0 0
10- Lack of awareness 0 0
Effect >>
Importance >>
Final Score
Causes
Relationship Scale
0 – No Relation, 1 – Week Relation, 3 – Moderate Relation, 9 – Strong Relation
MEASURE PHASE

Prioritization of CausesPrioritization of Causes
Mismatch
10
11- WIS not followed 3 3
14- Process sequence not followed 9 9
15- Tighting sequence not ok 0 0
16- Operator training 0 0
17- Improper visiblity 0 0
18- Improper space 0 0
Effect >>
Importance >>
Final
Score
Causes
Relationship Scale
0 – No Relation, 1 – Week Relation, 3 – Moderate Relation, 9 – Strong Relation
MEASURE PHASE

Who will
collecte
the data
How will
the data
be collected
How
will
the
data
be
used
How will
the data
be
displayed
Instrument Type Make Srl no.
Operating
Range
Least
count
Last
calibrated
on
Next
calibratio
n
due date
Method
to be
used
No. of
parts
to be
taken
No.of
appraisers
(& Name)
No. of
reading /
part
/appraiser
Acceptan
ce
criteria
Resp.
Target
Date
Attribute 50 3 1
As per
sheet
Pankaj 20/11/14
1-Anand
2-Gurdeep
3-Hargovind
SN.
Measurement system details Measurement system analysis plan
Performance
measure
(Ys /Xs)
Operational
Definition
Data
source
and
location
Sampling
method
sample
size &Freq.
When will
the data
be collected
Other data that
should be collected
at the same time
MSA Plan
Data Collection Plan
MSA PLAN FOR CRITICAL DIMENSIONS AT BIW

MSAMSA
MEASURE PHASE
Date :-
Part:-
Part Type:-
Parameter:-
Specification:-
Part A-1 A-2 A-3 B-1 B-2 B-3 C-1 0.3 C-3 Ref. Value
1 1 1 1 1 1 1 1 1 1 1
2 1 1 1 1 1 1 1 1 1 1
3 1 1 1 1 1 1 1 1 1 1
4 1 1 1 1 1 1 1 1 1 1
5 1 1 1 1 1 1 1 1 1 1
6 1 1 1 1 1 1 1 1 1 1
7 1 1 1 1 1 1 1 1 1 1
8 1 1 1 1 1 1 1 1 1 1
9 0 0 0 0 0 0 0 0 0 0
10 0 0 0 0 0 0 0 0 0 0
11 1 1 1 1 1 1 1 1 1 1
12 0 0 0 0 0 0 0 0 0 0
13 1 1 1 1 1 1 1 1 1 1
14 1 1 1 1 1 1 1 1 1 1
15 1 1 1 1 1 1 1 1 1 1
16 1 1 1 1 1 1 1 1 1 1
17 1 1 1 1 1 1 1 1 1 1
18 1 0 0 1 0 0 0 0 0 0
19 0 0 0 0 0 0 0 0 0 0
20 1 1 1 1 1 1 1 1 1 1
21 0 0 0 0 0 0 0 0 0 0
22 1 1 1 1 1 1 1 1 1 1
23 1 1 1 1 1 1 1 1 1 1
24 1 1 1 1 1 1 1 1 1 1
25 1 1 1 1 1 1 1 1 1 1
Attribute Last Calibration:- NA
WELD SHOP DEFECTS Calibration Status:- OK
Anand Gurdeep Hargovind
5-Aug-14 Gauge: NA
NA Gauge No.:- NA
NA Calibration Frequency:- 6 MONTH
CROSS TABULATION METHOD
ATTRIBUTE STUDY
26 1 1 1 1 1 1 1 1 1 1
27 1 1 1 1 1 1 1 1 1 1
28 0 0 0 0 0 0 0 0 0 0
29 1 1 1 1 1 1 1 1 1 1
30 1 1 1 1 1 1 1 1 1 1
31 1 1 1 1 1 1 1 1 1 1
32 1 1 1 1 1 1 1 1 1 1
33 1 1 1 1 1 1 1 1 1 1
34 1 1 1 1 1 1 1 1 1 1
35 0 0 0 0 0 0 0 0 0 0
36 1 1 1 1 1 1 1 1 1 1
37 0 0 0 0 0 0 0 0 0 0
38 1 1 1 1 1 1 1 1 1 1
39 0 0 0 0 0 0 0 0 0 0
40 1 1 1 1 1 1 1 1 1 1
41 1 1 1 1 1 1 1 1 1 1
42 1 1 1 1 1 1 1 1 1 1
43 1 1 1 0 0 1 1 1 1 1
44 0 0 0 0 0 0 0 0 0 0
45 0 0 0 0 0 0 0 0 0 0
46 1 1 1 1 1 1 1 1 1 1
47 0 0 1 0 1 1 0 0 1 1
48 0 0 0 0 0 0 0 0 0 0
49 1 1 1 1 1 1 1 1 1 1
50 1 1 1 1 1 1 1 1 1 1

MSAMSA
MEASURE PHASE
0 1 0 1
39 1 40 38 2 40
10.93 29.07 40 10.40 29.60 40
2 108 110 1 109 110
30.07 79.933 110 28.60 81.40 110
41 109 150 39 111 150
41.00 109 150 39.00 111 150
P0 - Pe Po 0.98 P0 - Pe Po 0.98
1 - Pe Pe 0.61 1 - Pe Pe 0.61
Kappa 0.95 Kappa 0.95
Miss Rate 2.564103
False Alarm 1.80
0 1 0 1
39 2 41 38 3 41
11.21 29.79 41 10.66 30.34 41
2 107 109 1 108 109
29.79 79.207 109 28.34 80.66 109
41 109 150 39 111 150
41.00 109 150 39.00 111 150
P0 - Pe Po 0.97 P0 - Pe Po 0.97
1 - Pe Pe 0.60 1 - Pe Pe 0.61
Miss Rate 2.564103
False Alarm 2.70
0 1 0 1
40 0 40 39 2 41
10.93 29.07 40 10.66 30.34 41
1 109 110 0 109 109
30.07 79.93 110 28.34 80.66 109
41 109 150 39 111 150
41.00 109 150 39.00 111 150
P0 - Pe Po 0.99333333 P0 - Pe Po 0.986667
1 - Pe Pe 0.61 1 - Pe Pe 0.61
Miss Rate 0
False Alarm 1.80
kappa kappa
Total
Count
Total
Count
Expected Count Expected Count
1
Count
1
Count
Ref value
Total
A
0
Count
C
0
Count
kappa kappa
A*C Cross Tabulation
C
Total C*Ref Value Cross Tabulation
Total
Count
Total
Count
1
Count
1
Count
Ref value
Total
B
0
Count
B
0
Count
kappa kappa
B*C Cross Tabulation
C
Total B*Ref Value Cross Tabulation
1
Count
Total
Count
Total
Count
A
0
Count
A
0
Count
1
Count
A*B Cross Tabulation
B
Total A*Ref Value Cross Tabulation
Ref value
Total

MSAMSA
MEASURE PHASE
CONCLUSION :
Target A B C
kappa > 0.75 0.95 0.93 0.97
Miss Rate Max 2% 2.56 2.56 0.00
False Alarm Max 6% 1.80 2.70 1.80
0.98 0.97 0.99
0.03 0.027 0.02
0.03 0.000 0.00
Effectiveness
Pfa
PM

DEFECT CONTRIBUTION
34
2
1
3
1
2
3
S.N. PROBLEM %
1 FRT STUD 60%
2 CENTER STUD 10%
3 JACK MTG 30%
MEASURE PHASE

I
SUB FRAME DIM SPECIFICATION
B 826
C 710
D 50
E 50
F 50
G 80
H 974
I 761
B
AD
C
F
G
E
H
Points Dimension
A 710
MEASURE PHASE

SUB FRAME DIM MEASUREMENTSUB FRAME DIM MEASUREMENT
MEASURE
P
O
I
N
T
SP
EC.
SB
NO.
937
15
SB
NO.
937
16
SB
NO.
9371
7
SB
NO.
9371
8
SB
NO.
937
19
SB
NO.
937
20
SB
NO.
9372
1
SB
NO.
9372
2
SB
NO.
9372
3
SB
NO.
93724
A 710 708 709 707 708 709 707 709 708 706 707
B 826 824 823 425 826 825 824 825 823 824 824
C 710 710 710 709 708 709 710 709 710 708 709
D 50 49 51 50 50 49 50 49 50 50 50
E 50 50 50 49 50 50 49 49 50 50 49
F 50 50 49 50 50 50 50 50 49 50 50
G 80 79 80 79 80 80 80 80 80 79 80
H 974 972 971 973 972 974 973 972 972 973 973
I 761 761 760 761 759 759 758 758 759 759 758
I
B
A
D
C
F
G
E
H
ALL DIM MEASURED IN mm BY MEASURING TAPE .ALL DIM MEASURED IN mm BY MEASURING TAPE .

1st
Step : -CMM Report Part Level (Before )
MEASURE & ANALYZE PHASE

FRAME SPECIFICATION
H
BA
D
C
F
G
E
B 826
C 710
D 50
E 50
F 50
G 80
H 974
Points Dimension
A 710
MEASURE

FRAME OBSERVED DATA
P
O
I
N
T
SPE
C. FRA
ME
NO.
570
7
FRA
ME
NO.
5708
FRA
ME
NO.
5709
FRA
ME
NO.
5710
FRA
ME
NO.
5711
FRA
ME
NO.
5713
FRA
ME
NO.
5714
FRA
ME
NO.
5715
FRA
ME
NO.
5716
FRA
ME
NO.
5718
A 710 710 711 713 712 712 711 712 712 711 712
B 826 825 823 424 826 824 823 824 824 823 824
C 710 709 708 709 708 709 708 708 709 710 709
D 50 50 49 50 50 49 50 49 49 50 50
E 50 50 48 49 50 50 49 49 50 49 48
F 50 50 49 50 50 50 50 50 50 50 50
G 80 79 80 79 80 80 80 80 80 80 80
H 974 974 977 975 978 977 976 975 976 975 975
A B
C
D
E F
G
H

40
40
S.NO. POINT NO. AXIS
NOMINAL
LH
NOMINA
L RH
ERROR LH ERROR RH ERROR LH ERROR RH
X -78 -78 -0.58 -1.61 -0.84 -0.75
A Y -355 355 0.26 0.6 0.11 0.66
Z -102.5 -102.5 -0.79 1.04 -1.23 -2.21
X 285 285 -0.59 -1.7 -1.59 -2.23
B Y -355 355 -1.45 -1.22 1.03 0.84
Z -110.5 -110.5 -2.88 -0.81 -0.84 -3.82
X 507.5 507.5 0.69 -2.81 -1.29 -2.35
C Y -355 355 -2.41 -1.77 0.27 -0.52
Z -122.5 -122.5 -3.16 -1.01 -3.44 -3.46
X 587.5 587.5 -0.23 -1.76 -2.19 -2.83
D Y -355 355 -1.92 -2.01 0.15 0.06
Z -122.5 -122.5 -3.59 -1.66 -3.66 -3.68
X 91 91 -1.2 -2.48 -1.75 -1.52
8 Y -412.95 412.95 -2.44 1.88 -2.23 2.83
Z -102.5 102.5 -1.38 0.67 -3.19 -2.7
X 507.5 507.5 -1.38 -2.59 -1.62 -2.56
9 Y -304.72 405.28 -1.59 -2.14 0.26 0.2
Z -122.5 -122.5 -4.57 -1.1 0.96 -0.28
X 587.5 587.5 -1.59 -1.58 -1.1 -1.55
10 Y -304.72 405.28 -1.48 -2.54 2.35 -1.99
Z -122.5 -122.5 -2.97 -2.05 0.37 -1.14
X -78 -78 -0.88 -2.11 -1.29 -2.55
11 Y -304.66 -304.66 1.62 -2.94 1.44 -3.16
Z -102 -102 0.39 0.57 -1.91 -0.92
SUPER ACE FRAME CMM REPORT
P1423822 (14.08.2014)
P1422978
(06.08.2014)
6
8
4
1
7
2
SUB FRAME MTG
3
5
Frame CMM Report

Analyze & Improve

Why –Why 1: Sub frame hole mismatch with frame nut
Why –Why 2: Position of holes in sub frame shifted
Why –Why 3: Sub frame dimension not ok as per CMM
Why –Why 4: Position of locating pin shifted in Sub frame
welding fixture.
42
Root Cause:-
Locating pin shifted
in Sub frame
welding fixture
WHY WHY ANALYSIS - 1

LH side bkt position shifted in +Y dir by 2.0
mm.
RH side bkt position shifted in +Y dir by
2.0 mm.
Correction on Side member for Sub frame mtg at M/S Autoline
IMPROVE PHASE

Jack Mtg. Hole position LH shifted in +Y
direction by 2.0 mm
Correction on Assy subframe at BIW 1C
Jack Mtg. Hole position RH shifted in +Y
direction by 2.0 mm
IMPROVE PHASE

45
CMM Report Part Level ( After )
IMPROVE PHASE

46
LH side bkt position corrected
in X dir by +2.0 mm.
RH side bkt position
corrected in X dir. By
– 2.0 mm
LH side bkt position
corrected in X dir by -2.0 mm.
+ 2.0 mm
corrected in X dir by 2.0 mm.
– 2.0 mm
Correction on frame at Supplier
IMPROVE PHASE

47
corrected in X dir by 2.0 mm.
– 2.0 mm
Correction on frame Jack Mtg. point at Supplier
IMPROVE PHASE

48
48
CMM Report Frame (After Improvement)
S.NO. POINT NO. AXIS
NOMINAL
LH NOMINAL RH
ERROR LH ERROR RH ERROR LH ERROR RH
X -78 -78 -0.2 -0.66 0.49 0.17
A Y -355 355 0.84 -0.55 1.15 1.03
Z -102.5 -102.5 1.19 1.94 0.57 1.04
X 285 285 -0.08 -1.19 0.54 -0.01
B Y -355 355 -0.29 -0.35 0.13 0.81
Z -110.5 -110.5 0.04 -0.61 -1.75 -0.69
X 507.5 507.5 0.21 -1.01 0.31 -0.33
C Y -355 355 -1.28 -0.74 -1.45 0.5
Z -122.5 -122.5 -0.54 2.35 0.02 -1.32
X 587.5 587.5 0.32 -1.01 -0.01 -1.03
D Y -355 355 -0.75 0.11 -1.1 0.77
Z -122.5 -122.5 1.62 -0.94 -0.36 -1.71
X 91 91 0.2 -1.45 0.33 -1.03
8 Y -412.95 412.95 -1.89 1.1 -1.06 0.74
Z -102.5 102.5 0.51 1.47 0.35 0.47
X 507.5 507.5 0.11 0.56 0.7 -0.85
9 Y -304.72 405.28 -0.39 1.03 -0.88 0.83
Z -122.5 -122.5 1.94 1.37 1.47 -1.89
X 587.5 587.5 0.36 -1.58 0.58 -1.02
10 Y -304.72 405.28 -0.33 0.09 -1.25 1.12
Z -122.5 -122.5 0.77 0.31 -1.87
X -78 -78 -0.6 -0.73 0.51 -1.54
11 Y -304.66 -304.66 1.26 -1.06 1.27 -1.2
Z -102 -102 1.35 -0.81 2.55 1.05
6
7
8
3
4
5
P1426791 (05.09.2014) P1427105 (10.09.2014)
1
SUB FRAME MTG
2
SUPER ACE FRAME CMM REPORT
P1426791 (11.8.14) P1427105(14.8.14)

Q-Star Advance Project 49© Copyright, Confidential, Tata Motors Ltd 49
IMPROVE PHASE

Why –Why 1: Sub frame hole mismatch with frame nut
Why –Why 2: Sub frame twisted during coil spring fitment.
Why –Why 3: Gap observed B/W resting block and sub
frame during coil spring fitment process.
Why –Why 4: Resting block wear out.
50
Root Cause:- Sub
frame twisted due to
resting block wear
out.
Why –Why 4: Check point not availed for resting block
condition in JH sheet.

51
DEVELOPMENT OF SOLUTION
710MM
705 MM
Before fitment of coil spring DIM
After fitment of coil spring
Coil spring fitment with Sub Frame

SUB FRAME DIM 710mmSUB FRAME DIM 710mm
ALL DIM MEASURED IN mmALL DIM MEASURED IN mm

53
Resting block wear out leads
to sub frame twisting
New resting block installed
DEVELOPMENT OF SOLUTION

IMPROVE PHASE

Why –Why 1: Sub frame hole mismatch with frame nut.
Why –Why 2: Sub frame long mbr twists after engine stuffing
operation due to high twisting moment .
Why –Why 3: Weight of Sub frame-engine assembly
concentrated only on 2 studs
Why –Why 4:Assembly mounted with only 2 studs before
rest of the studs/bolts are mounted.
55
Root Cause:- Twisting of sub
frame during engine stuffing
due to the use of only 2 studs
during the initial mounting
process.
Why –Why 5: Insufficient gap for stud qualifying B/W Engine
stuffing bed and sub frame.

SUB FRAME ASSY PROCESS SEQUENCE (BEFORE)
Two Center Stud (LH/ RH)
used to mount the engine carrying
sub frame
Mounting of remaining 8 studs
and 6 bolts was done after the
engine stuffing process.

SUB FRAME ASSY PROCESS SEQUENCE (AFTER)
2 Center studs+ 4 JACK Mtg studs
+ 4 FRONT Studs (LH/RH) are now
mounted before the engine stuffing
operation.
Remaining 6 bolts are mounted
after the engine stuffing process.

CURRENT STATUS (AFTER IMPLEMENTATION)

59
Improvement
Now stud qualifying is done before engine stuffing

Improvement
60
BEFORE
AFTER
Hole side increase 13 mm to 16mm

Improvement
61
BEFORE
AFTER
Sub frame Panel Side member LH
hole size increase 11 mm to 12.5 mm

Improvement
62
BEFORE
AFTER
Sub frame Panel Side member RH
hole size increase 12.5 mm to 14.0mm

IMPROVE PHASE

64
TARGET ACHIEVED
Sub Frame Rework % after improvement
IMPROVE PHASEReworkin%

Control

Hard Control
Soft Control
• Frame critical DIM. Inspection Gauge made.
• Frame critical DIM. Inspection Gauge made.
• Calibration of welding fixture done
• Trolley modification done to avoid transit damage.
• Work Instruction Updated & display in shop floor
• Check point added in JH sheet for resting block condition.
• Die spotting & polishing frequency revised & added in Die History card
• On job training provided to operators for Proper matching sub frame with frame.
Way of Control Mechanism
CONTROL PHASE

STANDARDISATION
67
2 + Front stud 4 SMALL SIDE INTERNAL THREAD PNEUMATIC GUN LH &
RH
4 JACK SMALL SIDE
CONTROL PHASE

68
CONTROL PHASE
JH CHECK SHEET

BEFORE AFTER
There was No gauge for checking sub frame
dimension 710mm.
Now we have gauge for checking sub
frame dimension 710mm.
BENEFITS:- Zero Rework , Quality improve , Cost & moral.
69
No Gauge for checking
sub frame dimension.
CONTROL PHASE

BEFORE AFTER
There was No gauge for checking frame
dimension 710mm.
Now we have gauge for checking frame
dimension 710mm.
BENEFITS:- Zero Rework , Quality improve , Cost & moral.
70
No Gauge for checking
frame dimension.
CONTROL PHASE

71
Frame to be check on checking fixture from supplier end.
CONTROL PHASE

72
4 TIMES / SEASON
BENEFITS
Tangible Benefits:-
We save rework manpower (2 in nos.) cost of 30000Rs. per month
30000 *12 (month)= 3,60,000 Rs. p.a.
4 Taps & 1 Conical bit per day (670Rs.) = 17420Rs. per month
17420* 12 (month) = 2,09,040 Rs. p.a.
4 Drill bits Cost per day (4900Rs.) = 127400Rs. per month
127400 * 12 = 15,28,800 Rs. p.a.
Total Amount = 20,97,840 Rs. Per annum
Cost saving of Rs 20.97 Lacs/ annum

 Eliminate customer complain.
 Improved presentation skill.
 Improved analytical knowledge.
73
Intangible Benefits:-
BENEFITS
 Knowledge about 6 Sigma tools.
 Improved team work & self
confidence.

YOUR ARE
74

Six Sigma Project Final

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