Post on 05-Jul-2018
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CHAPTER 1
INTRODUCTION
1. 1. INTRODUCTION
Today many of the small scale manufacturing companies in United States are facing problems in
order to become competitive in global market. One of the reasons is the manufacturing activities
are outsourced to low labor cost countries like India and China. (han! "! #$%$& 'owa)ays
due to an increased competition companies are looking forward to reduce total cost! lead times
and increasing the product *uality. This has created a need to implement lean and si+ sigma
strategies in manufacturing organi,ations. -ean Si+ Sigma approach to business process
improvement helps companies distinguish themselves from competitors by manufacturing
products with less waste! faster! better and at lower cost. -ean Si+ Sigma is a methodology! when
it implemented properly the company improves efficiency and gain competitive edge. Today
organi,ations are using different tools and techni*ues to improve and sustain in the market.
Currently! Si+ Sigma tools and -ean anagement are recogni,ed as most popular continuous
improvement initiatives and companies are using them widely. -ean Si+ Sigma pro/ect initiatives
start with understanding the current state of the 0usiness processes in organi,ation! then setting
up targets for future state of all activities. Si+ Sigma uses )1IC ()efine! easure 1naly,e
Improve and Control& framework and -ean uses tools like value stream mapping!2S program!
Single piece flow etc. Using these tools and techni*ues organi,ation can improve business
processes! the obstacles to achieve these improvements can be addressed by kai,en event. (Chen!
#$%$&
This pro/ect shows reduce the coolant consumption in tractor rim liners. To reduce the coolant
consumption by applying -ean Si+ Sigma tools such as Cause and 3ffect diagrams! root cause
analysis and brainstorming etc. This 4ro/ect addressed the root causes of problems in the process
of coolant consumption and recommended solutions and alternatives which led to more
optimi,ed processes and enhanced the operational system! eliminate different type of waste! and
increased the profit.
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1.2 COMPANY BACKGROUND
1.3 LEAN MANAGEMENT & SIX SIGMA
1 lean system emphasi,es the prevention of waste in terms of any e+tra time! labor! or material
spent producing a product or service that doesn5t add value to it. 1 lean system5s uni*ue tools!
techni*ues! and methods can help organi,ation to reduce costs! achieve /ustintime delivery! and
shorten lead times. 1s -ean systems are customer focused and driven this approach makes sure
that products or services produced and delivered at right time in right *uantity at right location at
right time with minimum costs incurred. 1 lean system allows production of a wide variety of
products or services! efficient and rapid changeover among them as needed! efficient response to
fluctuating demand! and increased *uality. -ean approach encourages the rapid response to
customer ever changing demands with focus on mass customi,ations rather than mass
production. -ean systems make the work flow more efficient! productive! and fle+ible to changes
in re*uirements. (aclnnes! #$$#&
6Si+ Sigma is a factbased! datadriven philosophy of *uality improvement that values defect
prevention over defect detection.7 (0rassard! #$$#& Si+ Sigma is also business philosophy of
focusing on continuous improvement by understanding customer needs! understanding current
business processes! and applying data collection methods. It is also methodology for organi,ation
to make sure those improvements done to improve the key processes. Si+ sigma tools and
techni*ues also used to identify which business process in the organi,ation would be benefited
most due to improvement effort.1.3.1 Brains!r"in#
It is a group or individual creativity techni*ue by which efforts are made to find a
conclusion for a specific problem by gathering a list of ideas spontaneously contributed by its
members.
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1.3.2 Ca$s% an %''%( ia#ra"
It is also called fish bone diagram show the significant and insignificant actions during a
process. It identifies many possible causes for an effect or problem and sorts the ideas into useful
categories. Often the e+perience of the speciali,ed knowledge of engineers and scientists
dominate the selection of factors.
1.3.3 R!! Ca$s% Ana)*sis
The 8ive 9hys approach to root cause analysis is often used for investigations into e*uipment
failure events and workplace safety incidents. The apparent simplicity of the 29hys leads
people to use it! but its simplicity hides the intricacy in the methodology and people can
unwittingly apply it wrongly. They end up fi+ing problems that did not cause the failure incident
and miss the problems that led to it. They work on the wrong things! thinking that because they
used the 29hys and the *uestions were answered! they must have found the real root cause.
1.+ OB,ECTI-E O THE STUDY
To determine the most critical :5s in the coolant consumption process and to eliminate the ;ital
:5s in the process to reduce the coolant consumption in tractor rim line.
1./ ORGANI0ATION O THE REPORT
This section provides a brief overview of the chapters for the convenience of the reader to easily
e+plore the contents of the report. In chapter# deals with literature review on reduce the coolant
consumption process using lean si+ sigma methodology. The problem statement and
methodology in chapter
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;arious work done on the welding process! optimi,ation of weld parameters by using the
statistical optimi,ation techni*ues are presented in the chapter.
2.1 TIG %)in# & Ta#$(i %(ni4$%
'irmalendhu!et al.! (#$%=& analy,ed to the improvement of ultimate load of stainless
steel > mild steel weld specimen made of tungsten inert gas (TI?& welding. -%@ orthogonal array
(O1& of Taguchi method has been used to conduct the e+periments using several levels of
current! gas flow rate and filler rod diameter. Statistical techni*ues analysis of variance
(1'O;1&! signaltonoise (SA'& ratio and graphical main effect plots have been used to study
the effects of welding parameters on ultimate load of weld specimen. The optimum welding
condition obtained by Taguchi method isB current %$$ 1! gas flow rate %D lAmin and filler rod
# mm. Confirmation test is confirms the improvement of the U- which also indicates the
validity of the present optimi,ation.
1vinash!et al.!(#$%
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Orthogonal arrays of Taguchi! the signaltonoise (SA'& ratio! the analysis of variance
(1'O;1&! and regression analyses are employed to find the optimal process parameter levels
and to analy,e the effect of these parameters on the weld properties. Confirmation test with the
optimal levels of welding parameters was carried out in order to illustrate the effectiveness of the
Taguchi optimi,ation method. 8rom the analysis of the results using the signaltonoise (SA'&
ratio approach! analysis of variance and Taguchi5s optimi,ation method! the following can be
concludedB 4eak current of %2$1! base current of H21 and pulse fre*uency of %2$ , are the
optimi,ed welding parameters for getting highest microhardness! smallest e*iu+ed weld grains
and minimum 1" width. Out of three selected parameters! peak current has the highest
contribution i.e. @%.2DJ.
4asupathy!et al.! (#$%
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ishore!etal.! (#$%$& have analy,ed the effect of process parameters in *ualitative manner
for welding of 1ISI%$=$ steel using processes of Shielded etal ?as 9elding (I? and TI?&.
Taguchi method is used to formulate the e+perimental layout arc voltage! arc current! welding
speed! no,,le to work distance and gas pressure predominantly influence weld *uality! even plate
thickness and backing plate too have their own effect. )esign of e+periments based on
orthogonal array is employed to develop the weldments. 1n -D orthogonal array is selected for
e+perimentation. The total variables are seven hence # H e+periments are re*uired for perfect
analysis! however it is impractical! time consuming and e+pensive to conduct such large number
of e+periments .
The result computed is in form of contribution from each parameter! through which
optimal parameters are identified for minimum defects. The e+periments with low current has
increased the J of variance of -O4 in both TI? and I? welding .igh welding speed resulted
in under fillF it is as high as Dmm# in TI? weldingF -ack of penetration is largely influenced by
the plate thickness in TI? weldingF current has an influence of about =2 J on under fillF
2.2 S5a%r D%'%(s
Teerade/! et al.! (#$%$& studied to determine an optimal condition of resistant spot welding
process in order to reduce a welding spatter problem. there were four factors considered as high
potential causes of welding spatters. They selected the factors are 3lectrical supply >single
!dual!aterial thickness heavy !normal! 9elding angle perpendicular! non
perpendicular!9elding position middle!flange 3ach factor consider as three levels and #⁴
factorial e+periment also conducted to test the effects of all possible combinations.
The result showed that three main factors namely 3! 91! and 94 had significant effects to
the defective parts whereas T was not significant.The optimal condition obtained from the
e+periments by using single pulse signal! normal thickness! perpendicular angle! and middle
position! a number of defective parts were reduced significantly from %#J to
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CHAPTER 3
PROBLEM STATEMENT AND METHODOLOGY
3.1 Pr!5!s% M%!!)!#i%s
3.1.1 DMAIC M%!!)!#*
)1IC methodology involves 2 steps )efine! easure! 1naly,e! Improve! and Control. This
method can be used to improve the current capabilities of current process where based on data
driven conclusions future state can be established.
D%'in% Pas%6 The goal of define phase is to define the pro/ect scope by understanding
background information about the process and its customers. Tools used in define phase as voice
of customer! pro/ect charter are used decide the scope of pro/ect and define boundaries of
improvement effort. It also identifies key stakeholders! time lines! improvement priorities! and
improvement targets at the beginning of pro/ect. The best representation of define phase can be
established by oshin planning or + matri+.
M%as$r% Pas%6 The goal of measure phase is to focus on improvement effort by gathering
information about current state of the process. Team has created data collection templates
according the area of improvement and worked on getting first hand data. easuring the right
data which can pin point location! occurrence point and rate of occurrence is re*uired to decide
the improvement priority and problem5s location. In measure phase team can gather istorical
data to come up with baseline for improvement. easure phase data collection effort leads to
more focused problem statement.
Ana)*7% Pas%6 The goal of analy,e phase is to establish the root causes of the problem and
confirm them with the data points. 1naly,e phase helps in collecting causes of the problem to
come up with root causes. 0raining storming! cause and effect diagram! histogram and fishbone
diagram are some of the tools which can be used in analy,e phase of the improvement.
I"5r!8% Pas%6 The goal of improve phase to work on improvement solutions based on define!
measure and analy,e phase outputs. Improve phase compares before and after process status to
develop and implement the process improvements. Improve phase not only generates the
solutions but also give feedback mechanism check the effectiveness of improvements.
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C!nr!) Pas%6 The goal of the control phase is to maintain and standardi,e the gains of the
improvements. Control phase also re*uire a continuous improvement effort to sustain the change.
Customer changing re*uirements need ma/or changes in process flowsF in that case improvement
team should be able to analy,e the changes for further improvements.
CHAPTER +
DMAIC METHODOLOGY
+.1 DEINE
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The 4roblem is defined in this phase. Geduction of coolant consumption in tractor GI line is
targeted. 9ith the help of process mapping! various stages in the rims process are identified is
shows the figure =.%.
Pr!9)%" Sa%"%n6 Geduction of coolant consumption in tractor GI line
Pr!:%( S(!5%6 Gework cost reduction K Muality improve
Tar#%6 onthly 2$$ litres to #$$ litres
i# +.16 Pr!(%ss Ma5 !' Tra(!r Ri" Lin%
+.1.1 I%ni'i(ai!n !' % Pr!9)%"
The problem description helps where the problem is locatedAoccurred is shown in the table =.%.
Ta9)% +.16 I%ni'i(ai!n !' Pr!9)%"
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+.1.1.2 Ca%#!ri7ai!n
• TYPE A ; inimum involvement of other department in solving them A can be solved by
the MC member itself.
• TYPE B ; Involvement of other department is a necessity.
• TYPE C ; 4roblem can be solved with management assistance.
+.1.2 S%)%(i!n !' Pr!9)%"
10
A < 1 3
C < 2B < +
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To identify the problem is located in GI line. Then to found the causes of the problem is based
on ranking related to product! *uality! cost! delivery! service! work environment is shows table
no.=.#.
Ta9)% +.26 S%)%(i!n !' 5r!9)%"
P=Pr!$(i!n> ?=?$a)i*> C=C!s> D=D%)i8%r*> S=Sa'%*> E=!r@ En8ir!n"%n
+.2 M%as$r% Pas%
)uring this phase! the key processes in the pro/ect lifecycle that affect the CTM (in this case!
product *uality&! were identified to be pro/ect study! e+ecution and delivery. easurements
related to the CTM are made in these phases. The field errors captured by the =9K%!root cause
K 9N 9N analysis as shown in 8igure =.#.%.
+.2.1 + & 1H Ana)*sis
The =9 K% is e+plained the 91T is the problem and 93G3 it is occur and 93' it is
occur! 9O K O9 much is the severity of the problemAprocess as shown in the figure =.#.%.
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Why?
Why?
Why?
Rim operation improper lubrication used
Coolant contamination changed
Rim scufng and scoring mark high
Foreign particles mix-up
Why?
Why?
Exist design11
CO!"ER #E$%RE
$ %ystem to be pro&ided to Re coolant cycle syste
i# +.2.16 +&1H
+.2.2 R!! Ca$s%s & * =* Ana)*sis
It is one of the simplest investigation tools easily completed without statistical analysis. 1lso
known as a 9hy Tree! it is supposedly a simple form of root cause analysis. 0y repeatedly
asking the *uestion! 9hyP5 you peel away layers of issues and symptoms that can lead to the
root cause of the coolant consumption as shown in figure =.#.#.
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D$rin# % !5%rai!n ir!n 5ars "i% an s% $5
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i# +.2.26 HY=HY ana)*sis
+.3 Ana)*7% 5as%6 4rocess performance was assessed using Causeand 3ffect diagrams! to
isolate key problem areas! to study the causes for the deviation from ideal performance! and to
identify if there is a relationship between the variables. 3+tensive brainstorming sessions were
held with team members to evolve these diagrams. 8igure =.
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+.3.1.2 Ca$s% an E''%( ia#ra"
-arge variation has been reported in the first phase. To reduce variations! analy,e the machine
and identify some factors which may affect the variation. 8inally! a fishbone diagram is formed
as shown in 8igure =.
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M S PROBLEMCONSIDERED NOT
CONSIDERED
REASON OR
ELIMINATION
Man I"5r!5%r (!!)an !i) "i% C!nsi%r%
Man Uns@i))% !5%ra!r C!nsi%r%
Man I"5r!5%r (!!)an !i) ')! C!nsi%r% SOP A8ai)a9)%
Man In(!rr%( L!(ai!n !' ri" N! (!nsi%r% P%ri!i( PM
Man T!!) )i'% #!n% N! (!nsi%r% P%ri!i( Ins5%(i!n
Ma(in
%C!!)an (!na"inai!n C!nsi%r%
M%! T!!) :a n! s$''i(i%n N! (!nsi%r% P%ri!i( PM
Man C!!)an s5i))a#% in ')!!r C!nsi%r%
Ma%ria
)L%ss%r i(@n%ss "a%ria) N! (!nsi%r%
C%(@ 5!in in irs !''
ins5%(i!n
M%!as% an #r%as% "i%
(!!)an !i)C!nsi%r%
M%!
I"5r!5%r (!!)an 5i5%
r!$in# N! (!nsi%r%
E5anin# B)!(@ s%in# 9*
PTA
Ma(in
%
L%a@a#% * !i) "i% '!r
(!!)anC!nsi%r%
+.3.1.+ A'%r E)i"inai!n !' Min!r E''%(s = Ca$s%s & E''%( Dia#ra"
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i# +.3.2 E)i"inai!n !' Min!r E''%(s
+.3.1./ E''%(s !' % Pr!9)%"
Gim Gework more
Gim *uality effect for rim rust form problem high
Gim scuffing mark and scoring mark high
Our internal customer Gim feeding time delay
4ickling cost very high
igh operator fatigue and Skilled operator is re*uired
+.3.1. I"5!ran(% !' % Pr!9)%"6
achine bit accumulated coolant oil daily cleaning and fill up the barrel .
9eekly @ barrel oved to 3T4 plant
Coolant removed out e+tra #man power and barrel moved forklift re*uired
3ffect coolant spillage floor
Coning machine separate coolant used
onthly coolant oil consumption 2$$ -ts
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+.+ I"5r!8% 5as%
In the improve phase! first make some improvements based on results of the analy,e phase and
assess the reduction of rim line coolant consumption system. 0ased on current process flow! to
eliminate the root causes of the problem and improved process flows. So it has decided to
improve these problems by understanding current process flows and developing improved
process flows to address the causes of more consumption rate. The coolant recycle unit machine
as shown in figure =.=.%! magnetic fitter is shown in =.=.#! oil skimmer shown in =.=.< K before
and after machine set up shown in =.=.=.
+.+.1 D%8%)!5in# S!)$i!n
1 coolant recycling unit introduced
Iron parts removed out purpose magnetic duct collator
0ucket #$ micron paper filter unit
Coolant mi+ed oil removed purpose oil skimmer unit provided
This unit connects the three machines
• Coning• Goll former %
• Goll former #
i# +.+.16 C!!)an R%(*()% Uni
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i# +.+.26 Ma#n%i( i)%r Uni
i# +.+.36 Oi) S@i""%r Uni
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i# +.+.36 B%'!r% & A'%r C!!)an Tan@
+./ C!nr!) 5as%6 ;arious measures identified to improve the process are documented and
institutionali,ed. Control phase established to monitor the process of coolant recycle unit.
+./.1 B%n%'is
Tan#i9)% B%n%'is
Gust free
Cost saving directly
Gework reduced
4roductivity improved
0reakdown occurrence reduced
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Inan#i9)% B%n%'is
Operator fatigue reduced
SOC 3liminated
Improved Safety
?ain Confident to solve problems
Qob Satisfaction
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CHAPTER /
CONCLUSION
/.1 $$r% S$*
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REERENCES
%. 1vinash s. 4acha-! 1mol bagesar Taguchi Optimi,ation of 4rocess 4arameters in 8riction‟
welding of @$@% 1luminium 1lloy and #.1noop C 1! 4awan umar 1pplication of Taguchi ethods and 1'O;1 in ?T19 4rocess‟
4arameters Optimi,ation for 1luminium 1lloy H$
H.rishnaiah ! Shahabudeen 4! 1pplied design of e+periments and taguchi methods‟ ! "I
learning !vt ltd$)elh #$%