PROJECT TITLE : ELIMINATION OF CUSTOMER COMPLAINT BY INTRODUCTION OF MISTAKE PROOFING (POKA YOKE) IN PROCESS THROUGH TECHNOLOGY IMPROVEMENT

OBJECTIVES : To eliminate the customer complaint in Bracket Bush & Oilseal Assy Operation by introducing mistake proofing (POKA YOKE) arrangements in the bush pressing machine by use of new technology.

ABSTRACT : In Bracket Bush and Oil seal Assy Operation there is a frequent chance of operation being missed (or) partial operation being missed (or) possibilities of wrong assembly. So there were customer complaints because of this issues. Therefore, we had an deep FMEA review analysis on this operation with the CFT members by identifying and addressing all the potential failure modes, potential effects of failure, potential causes of failure and the process controls such as prevention and detection which are all required. After the analysis we have decided to incorporate several mistake proofing controls in the Bracket Bush and Oilseal Assy machine to prevent the wrong component being produced. In the present bush pressing machine, which we are having, doesnt have the technology to incorporate the mistake proofing controls. Therefore we have raised the sanction for new technology PLC controlled machines to incorporate our mistake proofing controls in the machine to prevent the production of wrong components.

TOOLS USED : Failure mode and effects analysis (FMEA) is a method (first developed for systems engineering) that examines potential failures in products or processes. It may be used to evaluate risk management priorities for mitigating known threat-vulnerabilities. FMEA helps select remedial actions that reduce cumulative impacts of life-cycle consequences (risks) from a systems failure (fault). By adapting hazard tree analysis to facilitate visual learning, this method illustrates connections between multiple contributing causes and cumulative (life-cycle) consequences. It is used in many formal quality systems such as QS 9000 or ISO/TS 16949. The basic process is to take a description of the parts of a system, and list the consequences if each part fails. In most formal systems, the consequences are then evaluated by three criteria and associated risk indices:

* severity (S), * likelihood of occurrence (O), and (Note: This is also often known as probability (P)) * inability of controls to detect it (D) Each index ranges from 1 (lowest risk) to 10 (highest risk). The overall risk of each failure is called Risk Priority Number (RPN) and the product of Severity (S), Occurrence (O), and Detection (D) rankings: RPN = S O D. The RPN (ranging from 1 to 1000) is used to prioritize all potential failures to decide upon actions leading to reduce the risk, usually by reducing likelihood of occurrence and improving controls for detecting the failure.

DELIVARABLES : Since the new PLC machines have been procured, we have incorporated all the POKA YOKE controls, therefore chance of producing a wrong component is nullified and hence the customer complaint has been eliminated.