Ssgb Prework

8/18/2019 Ssgb Prework

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Six-Sigma Green Belt Workshop (Pre-work)

Six-Sigma Green Belt

Pre-work

Focus of this program is not just on knowledgeenhancement but on practical application of Six-Sigma methodology for solving a real life concerns.In order to make this easy, we will be focusing all

our workshop discussions and exercises a lot onactual project allocated to you. It is thereforenecessary to gather some basic information,historical data, facts and gures pertaining toproblems assigned to you.

!ry to collect as much information as possible, as


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Problem to be solved : Rear Spring breakage

Current level : 1.3arget level : 0.4

TEAM

Names Role Organization /

DeptSponsor

Mr. Madhu Bojja Cha pion ! Guide "oundr#

Mr. Manish $ain %eader &Green

Be'()*+

Mr. P. . as Me ber Cus(o er Suppor(

Mr. ikra Raj Me ber *+Mr. inee( Shar a Me ber /RC



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Six-Sigma Green Belt Workshop (Pre-work)Six-Sigma Green Belt Workshop (Pre-work)

Ba!kground o" the problem # "ailure mode(s)


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Ba!kground o" the Problem

Where thisproblem is

coming?

Where this problemis not coming?

Models /vehicles

S 1 13 %PS401 , %P 311

Lines %ine 2 %ine 3!ppliers M!s +ka' Springs M!s $ai, M!s Soni +u(o

"art n!mbers 2 323240011 2 232400112,2 4132400101

#one /c!stomers

Fill the rows as applicable "Fill the rows as applicable "

Declaration $Declaration $ he abo e in5or a(ion is au(hen(i6 and 7 ha e (he ba6k-up e iden6es 5ohe abo e in5or a(ion is au(hen(i6 and 7 ha e (he ba6k-up e iden6es 5o


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Ba!kground o" the Problem

Fill the failure mode tree and substantiate with data #I$!%Fill the failure mode tree and substantiate with data #I$!%

Declaration $Declaration $ he abo e in5or a(ion is au(hen(i6 and 7 ha e (he ba6k-up e iden6es 5ohe abo e in5or a(ion is au(hen(i6 and 7 ha e (he ba6k-up e iden6es 5o


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Six-Sigma Green Belt Workshop (Pre-work)Six-Sigma Green Belt Workshop (Pre-work)C$% # Prowa!

ARVIND_MOTORS_PVT _LTD

0 00 46 2014 SUSPENSION

SPRING LEAFBROKEN - REAR

REAR RIGHT AUXSPRING BROKEN

MAT373339D1N14420

11 2013 !"16"2014

1613 1613-LPT

2!13 2"1#"2014

!"#"2014 REAR LEAF SPRING BROKEN THIS VEHI$LE REPORTED TO OUR%ORKS %ITH ABOVE SAID

$OMPLINT ONOBSERVATION THEREAR LH SIDE 4TH LEAF BROKENINTO PIE$ES AT ABOUT 4#! MM

FROM THE $ENTER BOLT HOLETO%ARDS REAR END SIDE OF THESUSPENSION $HE$KED THE

SPRING SET $ENTER BOLT ANDD U$LAMP FOUND INTA$T NO AN&MODIFI$ATION DONE ON THE

$HASSIS FRAME NOT SUSPENSIONS&STEM

POPULAR MEGAMOTORS 'I( LTD

0 12 31 2013 SUSPENSION


REAR RIGHT LEAFSPRING BROKEN

MAT373170D1)11!!2

09 2013 1"10"2014

1613 1613-SK 2696 10"2#"2013

1"10"2014 ABNORMAL SOUND FROM REARSUSPENSION AND VEHI$LE OFFROAD ATALAN$HER& %HI$H IS!6KMSFROM OUR %ORKSHOP

%E DEPUTED OUR ME$HANI$ FORONSITE REPAIR DURING

INSPE$TION%E $HE$KED ANDFOUND THAT REAR RH SIDE

SE$OND AUXILIAR& LEAF SPRING%AS IN BROKEN AND 1ST AUX LEAF%AS IN $RA$KED $ONDITION ALSO

%HILE DISMANTLED BOTH SIDE

LEAF SPRINGS ASS& AND FFOUNDTHAT $ENTRE HOLE PRESENT INMOST OF THE LEAF SPRING %AS IN

ELONGATED $ONDITION AND$ENTRE BOLT HAVING EX$ESS

PLA&DUE TO THIS HOLEELONGATION MOST OF THE SPRING

LEAVAES PRESENT IN THE ASS&%ERE N SEVEREL& RUSTED

$ONDITION

)AIKA_MOTORS_LTD 01#6! 2013 SUSPENSION



MAT373172D1H104!7

0# 2013 12"7"2013

1613 1613-SK 2779 10"2#"2013

12"6"2013 REAR SPRING LEAF BROKEN REAR LHS 2ND SPRING LEAFFOUND BROKEN NO MODIFI$ATIONOBSERVED IN SUSPENSION *MAKE-

NOT FOUND IN LEAKF SPRING+

BHANDARI_AUTOMOBILES_PVT_LTD

0 0# 20 2013 SUSPENSION



MAT3##344D2H0#337

0# 2013 12"27"2013

1613T$1613T$-LPT

291! 9"27"2013

12"1#"2013

LEAF SPRING BROKEN OBSERVED REAR HELPER SET MAINLEAF SPRING BROKEN FROM

MIDDLE NO OUTSIDE IMPA$T ANDNO SU$H MODIFI$ATION ON

SUSPENSION FOUND SUSPE$TEDLEAF SPRING MATERIALHARDENING IMPROPER

ABT_INDUSTRIES_LTD0 0926 2013 SUSPENSION



MAT3730#!D2F06470

06 2013 3"19"2014

1613 1613-SK 2936 2"20"2014

3"1!"2014 REAR RHS SIDE SUSPENSIONNOISE

IN OUR INSPE$TION FOUND #TH AND 7TH LEAF BROKEN %HILE THE

VEHI$LE IN RUNNING %ERE$EIVED THE VEHI$LE ONL& THE

HALF OF THE LEAF OF 7TH AND#TH DID NOT FIND OUT THE

REMAINING LEAF

ARVIND_MOTORS_'P(_

LTD

0 19 6# 2013 SUSPE

NSION

SPRING LEAF

BROKEN - REAR

REAR RIGHT LEAF

SPRING BROKEN

MAT373170D1K12

730

10 2013 11"20"2

013

1613 1613-SK 301! 10"31"20

13

11"19"201

3

REAR SUSPENSION NOIS& FOUND REAR LH MAIN LEAF

$UT"BROKEN $AUSING THE$OMPLAINT

D, .,/ N , $. S/. P$R&, / $

A / D,5 / 8 D,5 / 8 $ 55 5 8P/ :M 8 $. D M :,. S;< M :,. KM S ., D ,

$ -R, -D $;5 ,/ $ . 8 I8=,5 8

D, .,/ N , $.S/.P$R&, /

$ A / D,5 / 8 D,5 / 8 $ 55 5 8

P/ :M 8

$. D

M :,.

S;<M :,. KM

S .,D ,

$ -R, -D $;5 ,/ $ . 8 I8=,5 8


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rends ('&& &&*)


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rends ('&& &&* - +'+ )


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,ealer Wise *nal sis


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Pro!ess Steps

)apture step-by-step pics and complete below *ow diagr)apture step-by-step pics and complete below *ow diagr


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$nput &aterial ,etails

$lease ll the table below for all items which are under$lease ll the table below for all items which are underproject scope along with key interface parts "project scope along with key interface parts "

%tems !ppliers+ear Spring bracket 'FF) , Fie Sphero

Spring pin ultitech, !+ear Spring Shackle 'FF) , Fie Sphero

/ottom Saddle of+ear 0xle ! 121

3-bolt Steel )ity, 4.S.0uto


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,rawings


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P/,

#attach $F2 of the#attach $F2 of theconcerned process(concerned process(


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/&0*

#attach F '0 of the#attach F '0 of theconcerned processconcerned process

If possible, try to getIf possible, try to get

2F '0 from '+) or2F '0 from '+) orSupplier(Supplier(

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