A project Report

On Reduction in Assembly Line Lapses in first Shot Ok

Compiled by Anshul Bohara (08ME1014) Department of Mechanical Engineering IIT KHARAGPUR

FIRST-SHOT OK ERRORS DATA COLLECTION

First-Shot ok means producing the product near 100% perfect as per the required out-going quality. It means it is free from most of the common defects. Every manufacturing company tries and wants its manufactured goods to be 100 percent acceptable. This means there should be no rejection of the products. In order to achieve 100 percent satisfactory goods, proper care has to be taken in the manufacturing and assembling division of any plant.

In TATA Motors, various parts of the truck, some manufactured in plant itself and some parts procured from other companies are assembled in the TRUCK ASSEMBLY. Since there are many stations and in most of them operations are done manually and in each station different operation is performed, there are many possibilities of errors. There can be error related to inaccuracy, overlooking or missing of parts etc. The truck after assembly goes to testing for checking of errors or faults. The errors are then detected during testing and the truck is then sent to rectification area if any defect is found. After taking required actions/changes in rectification area, the truck is sent to dispatch.

A Sample First shot Ok Report

An Overview of 1 Shot OK Analysis is been given from next page onwards

1 Shot OK Analysis of April Line 2

Data
Assembly lapses Deficiency Material Defect TruckIII TS/PPC/ TTIL/NPI/ADD/ERC Material Handling Issue Engine HVAL TCL Frame shop HVTL 239 678 155 52 38 30 25 25 24 10 2
Fouling Fastener Loose Parts missing Assembly not OK Damaged part fitted

56 40 16 102 30

1 Shot OK Analysis of April Line 1

Data
Model No.
SK 1616 SK 1613 LPT 2518 LPT 1613 SE 1616 LPT 1616 SE 1613 LPT 2513 LP 1512 LPT 3118TC LPT 2513TC LPT 3118 LPT 1613TC SK 1613TC LPT 2518TC SE 1613TC LP 1512TC LPT 2515 LPT 2523 SK 1616/36 LPT 2515TC LPT 2523TC LOT 2518 LP 1613 LPK1616 LPS 3518

No. of defects
272 207 199 166 143 116 54 49 44 25 23 17 15 10 9 9 8 3 3 3 2 2 1 1 1 1

Agency
Assembly lapses Deficiency TruckIII

No. Of Defects
281 551 132

Material Defect Engine Material Handling Issue TS/PPC/ TTIL/NPI/ADD/ERC HVAL TCL Frame shop HVTL

127 61 49 43 41 41 38 19

Type Of Defects
Fouling Fastener Loose Parts missing Assembly not OK Damaged part fitted

No. Of Defects
35 56 59 113 20

1 Shot OK Analysis of May Line 1

Data
Model No.
SK 1616 SK 1613 LPT 1616 LPT 1613 SE 1616 SE 1613 LP 1512 LP 1512TC LPT 1613TC LPT 2518 LPT 2518TC SK 1613TC LPT 2513TC Agency LPT 2513 Fouling LPT 3118 SE 1613TC LPT 2515 Fastener Loose LPT 2515TC Parts missing Assembly not OK Damaged part fitted

No. of defects
314 248 201 185 164 81 59 47 47 85 28 16 44 25 38 12 2 1 75 1 44 173 64

No. Of Defects

Assembly lapses 393

Deficien cy 495

Truck III 207

Material Defect 231

Frame shop 75

Engin e 76

Material Handling Issue 60

HVA L 47

TS/PPC/ TTIL/NPI/ADD/ERC 31

TC L 48

H V T L 1 3

1 Shot OK Analysis of May Line 2

Data
Defect Type Fouling Fastener Loose Part missing Assembly not OK Damaged/Deform part fitted

No. Of Defects 83 35 7 122 55

Agency Assembly lapses Deficiency Material Defect TruckIII TS/PPC/ TTIL/NPI/ADD/ERC HVAL TCL Material Handling Issue Frame shop Engine HVTL Forge div.

No. Of Defects 302 365 157 73 57 43 39 26 20 11 4 1

Model No.
LPT 3118 LPT 3118TC SD 1015 LPK 1615 SA 1212 LPT 1615 LPT 2518 LPT 1615TC SD 1015TC LPK 2518 LPT 2518TC LPK 2518TC LPK 2516 LPK 1615TC LPK 1616 LPT 2516TC LPT 1618 LPT 2516 LPTA 715TC LPS 3518TC LPTA 715 LPT 2513 LPK 2516TC

Quantity
263 87 69 52 49 42 38 34 33 32 32 30 29 28 27 23 20 18 18 17 17 16 14

Model No.
LPS 3518 SA 1212TC SAK 1212TC LPK 1518 LPT 1618 TC SAK 1212 LPT 3118 TC LPTA 713TC LPTA 713 LPS 4018 LPS 4018TC LPT 1618 Tilt LPT 2518 Tilt LPT 3118 Tilt LPK 1015 LPT 1613 Tilt LPT 1618LHD LPT 2513TC LPT 2515 LPT 3118TC (Tilt) LPT 3118Tilt LPT 713 LPT 715

Quantity
13 11 10 7 7 6 4 4 3 2 2 2 2 2 1 1 1 1 1 1 1 1 1

Detailed Analysis of Line- 2 1 SHOT OK

1.

Detailed Pareto Analysis of MAY Line- 2 1 SHOT OK

In this section various Assembly line Lapses have been categorized to various defect categories such as Incomplete Operation, Fastener Loose, wrong layout, kinked, leakage, deformed/damaged part fitted, Equipment Malfunction, Fouling etc . Firstly Pareto of various defect contributing models was made, then Pareto and pie charts of various defects causing agency was made, then by the use of 80-20 rule various defect types in assembly line lapses were analyzed and within those defects type again by the use of 80-20 rule models in which those defects occurred were analyzed.

Model Wise Distribution of DefectsModel wise Defects Contribution

S.N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Model LPt3118 TC LPT1615 TC SA1212 TC LPK1615 TC LPT2516 TC LPT2518 TC SD1015 TC LPK2516 TC LPT2513 TC LPK2518 TC LPTA715 TC LPK1616 697 LPT1618 TC SAK1212 TC LPS3518 TC LPS4018 TC LPT3118 T/cab LPTA713 TC LPT1613 TC LPT2515 TC Defect qty 81 33 21 19 14 14 14 12 12 11 10 7 7 7 6 2 2 2 1 1 %age Contr 29.3 12.0 7.6 6.9 5.1 5.1 5.1 4.3 4.3 4.0 3.6 2.5 2.5 2.5 2.2 0.7 0.7 0.7 0.4 0.4 Cumm% 29.3 41.3 48.9 55.8 60.9 65.9 71.0 75.4 79.7 83.7 87.3 89.9 92.4 94.9 97.1 97.8 98.6 99.3 99.6 100.0

Defect Distribution

Type

Total

276

Contribution of Defects
S.N . 1 2 3 4 5 6 7 8 9 Defect Description Incomplete Operation Fouling Wrong Layout Fastener Loose Kinking Deform & Damage Equipment Malfunctioning Leakage Plant-3 Defect qty 113 64 35 21 17 14 6 5 1 %age Contr 40.9 23.2 12.7 7.6 6.2 5.1 2.2 1.8 0.4 100.0 Cumm% 40.9 64.1 76.8 84.4 90.6 95.7 97.8 99.6 100.0

Total

276

Total Defect Contribution

Contribution of Defects
S.N . 1 2 3 4 5 6 7 Defect Description Material Deficiency Assly Lapses-I & II Material Defect (SQIG) Cab & Cowl TCL & 697 Engine HVAL & HVTL TS & PPC Defect qty 810 606 293 223 146 90 77 %age Contr 36.1 27.0 13.1 9.9 6.5 4.0 3.4 100.0 Cumm% 36.1 63.1 76.1 86.1 92.6 96.6 100.0

Total

2245

Model wise Defect Contribution in Assembly line lapses

Model wise Defects Contribution
S.N . 1 2 3 4 5 6 7 8 9 10 Model LPT3118 TC LPT1615 TC SA1212 TC LPK1615 TC LPT2516 TC LPT2518 TC SD1015 TC LPK2516 TC LPT2513 TC Others Defect qty 81 33 21 19 14 14 14 12 12 56 %age Contr 29.3 12.0 7.6 6.9 5.1 5.1 5.1 4.3 4.3 20.3 100.0 Cumm % 29.3 41.3 48.9 55.8 60.9 65.9 71.0 75.4 79.7 100.0

Total

276

Model Wise Defect Contribution in Defect type Incomplete Operation

Model wise Defects Contribution
S.N . 1 2 3 4 5 Model LPT3118 TC LPK2516/2518 TC LPT/LPK1615 TC SA1212 TC Others Defect qty 32 21 15 9 36 %age Contr 28.3 18.6 13.3 8.0 31.9 100.0 Cumm % 28.3 46.9 60.2 68.1 100.0

Total

113

Model Wise Defect Contribution in Defect type Fastener Loose

Model wise Defects Contribution
S.N. 1 2 Model LPT3118 TC Others Defect qty 11 10 %age Contr 52.4 47.6 100.0 Cumm% 52.4 100.0

Total

21

Model Wise Defect Contribution in Defect type Wrong Layout

Model wise Defects Contribution

S.N . 1 2 3 4 Model LPT1615 TC SD1015 TC LPT3118 TC Others Defect qty 13 6 4 13 %age Contr 36.1 16.7 11.1 36.1 100.0 Cumm% 36.1 52.8 63.9 100.0

Total

36

2.

Detailed Pareto Analysis of June Line- 2 1 SHOT OK

Model Wise Distribution of DefectsModel wise Defects Contribution
S.N. 1 2 3 4 5 6 7 8 9 Model LPK 1615 LPK 2518 LPT 3118TC LPT 1615 LPK 1615TC LPT 1618 LPT 2516TC LPK 2516 LPT 2518 Defect qty 46 36 33 19 10 10 10 9 9 %age Contr 18.32669 14.34263 13.14741 7.569721 3.984064 3.984064 3.984064 3.585657 3.585657 Cumm% 18.32669 32.66932 45.81673 53.38645 57.37052 61.35458 65.33865 68.9243 72.50996

10 11 12 13

LPT 1615TC LPT 2516 SA 1212 Others

7 7 7 48

2.788845 2.788845 2.788845 19.12351

75.2988 78.08765 80.87649 100

Defect Type Distribution

Contribution of Defects Defect Description Defect qty %age Contr Incomplete/Faulty Operation Total Fouling Total Wrong Layout Total Damaged/Defective Part Total Fastner Loose Total Kinked Total Equipment Malfunctioning Total Leakage Total Plant 3 Total Total 152 75 24 17 9 6 3 2 1 52.60 25.95 8.30 5.88 3.11 2.08 1.04 0.69 0.35 289

S. N. 1 2 3 4 5 6 7 8 9

Cumm% 52.60 78.55 86.85 92.73 95.85 97.92 98.96 99.65 100.00

Total Defect Contribution -

Contribution of Defects
S.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Defect Description Assembly lapses Total Deficiency Total Material Defect Total Truck III Total TS/PPC/ TTIL/NPI/ADD/ERC Total TCL Total Material Handling Issue Total TruckIII Total HVAL Total Frame shop Total Engine Total HVTL Total Material Handling Total Forge div. Total Total Defect qty 310 290 275 98 85 69 41 35 28 8 7 7 3 2 1258 %age Contr 24.6 23.1 21.9 7.8 6.8 5.5 3.3 2.8 2.2 0.6 0.6 0.6 0.2 0.2 100 Cumm% 24.6 47.7 69.6 77.3 84.1 89.6 92.8 95.6 97.9 98.5 99.0 99.6 99.8 100.0

Model Wise Defect Contribution in Defect type Incomplete/Faulty Operation -

Model wise Defects Contribution

S.N. 1 2 3 4 5 6 7 8 Model Defect qty %age Contr Cumm%

LPT 3118 Total LPK 2518 Total LPK 1615 Total LPT 3118TC Total LPK 1615TC Total LPT 1615 Total LPT 1615TC Total others

35 25 20 17 9 5 5 27

23.0 16.4 13.2 11.2 5.9 3.3 3.3 23.7

100.0

23.0 39.5 52.6 63.8 69.7 73.0 76.3 100

Total

152

Model Wise Defect Contribution in Defect type Fastener Loose

Model wise Defects Contribution
S.N. 1 2 3 4 5 6 7 8 9 Model Defect qty %age Contr Cumm%

LPK 1615 LPT 3118 LPK 2518 LPT 1615 LPT 3118TC LPT 2513 LPT 2516TC LPK 2516 Others

16 11 6 6 6 5 5 4 16

21.33% 14.67% 8% 8% 8% 6.67% 6.67% 5.33% 21.33%

100.0

21.33% 36.00% 44.00% 52.00% 60.0% 66.6700% 73.3400% 78.6700% 100

Total

75

Model Wise Defect Contribution in Defect type Damaged/Defective part Fitted

Model wise Defects Contribution
S.N. 1 2 3 4 5 6 7 Model Defect qty %age Contr Cumm%

LPK 1615 Total LPT 2518 Total LPK 2518 Total LPT 1615 Total LPT 3118 Total LPK 1615TC Total others

3 3 2 2 2 1 4

17.64% 17.64% 11.76% 11.76% 11.76% 5.88 23.66

100.0

17.64% 35.28% 47.04% 58.80% 70.56% 76.44 100

Total

152

Action Plan
Based on Pareto Analysis Action Plan was prepared taking into account defect types and Truck models ,also a check sheet was prepared.

Action Plan for Fateners Loose

S.N.
1 2 3

Defects Description
FUPD m ounting bolt loose W heel choke m ounting bolt loose Unloader v alav e pipe clam ping loose

Model
LPT3118 LPT3118 LPT3118

Action T aken

Resp Person

PDC
Im plem ented

After tigtening the bolt the operator is to O S Yadav confirm it by putting yellow paint.

After tigtening the bolt the operator is to Naresh Prasad Im plem ented confirm it by putting yellow paint. After tigtening the bolt the operator is to P S rao confirm it by putting yellow paint. Im plem ented

Action Plan for W rong Layout

S.N.
1

Defects Description

Model

Action T aken

Resp Person

PDC

Nylon bunch not pressed in bkt near stg gear box LPT1615 T C Nylon bunch not passing through eye clam p below cab Nylon bunch routing incorrect below 3rd XM

Nylon bunch was getting tied with the stg box so that it could not foul with clutch Naresh Prasad Im plem ented lev er. O perator awareness giv en. Naresh Prasad Im plem ented

SD1015 TC

LPT1615 T C

Eye clam p introduced below cross m em ber so that it could not foul with propK Banerjee S shaft.

Im plem ented

Action Plan fo r Incomp lete Op eration

S.N. Defects Description Model Action T aken Resp Person PDC

Electrical cable connection not done.

LPT3118 T C

A checksheet for all electrical connection in 3118 has been m ade so that no Sankalp electrical connection could be m issed. After fitm ent of tyre the operator is to confirm the stem v alv e position by putting yellow paint.

03.06.11

Stem Valv e position W rong

LPT3118 T C

Sankalp

Im plem ented

3 4

Silencer stopper ex cess gap Diesel Q ty less, engine not started.

LPT3118 T C LPT3118 T C

Feedback giv en to SQ A for analysis & Lobo Thom os counterm easure. Now the operator writes the actual filled qty in the register from the diesel dispenser. O perator awareness giv en. Rajat Im plem ented

Hyd pipe not clam ped from radiator bkt.

LPK2516 TC

Rajat

Im plem ented

Action Plan for Fateners Loose

S.N.
1 2 3

Defects Description
FUPD m ounting bolt loose W heel choke m ounting bolt loose Unloader v alav e pipe clam ping loose

Model
LPT3118 LPT3118 LPT3118

Action T aken

Resp Person

PDC
Im plem ented

After tigtening the bolt the operator is to O S Yadav confirm it by putting yellow paint.

After tigtening the bolt the operator is to Naresh Prasad Im plem ented confirm it by putting yellow paint. After tigtening the bolt the operator is to P S rao confirm it by putting yellow paint. Im plem ented

Action Plan for W rong Layout

S.N.
1

Defects Description

Model

Action T aken

Resp Person

PDC

Nylon bunch not pressed in bkt near stg gear box LPT1615 T C Nylon bunch not passing through eye clam p below cab Nylon bunch routing incorrect below 3rd XM

Nylon bunch was getting tied with the stg box so that it could not foul with clutch Naresh Prasad Im plem ented lev er. O perator awareness giv en. Naresh Prasad Im plem ented

SD1015 TC

LPT1615 T C

Eye clam p introduced below cross m em ber so that it could not foul with propK Banerjee S shaft.

Im plem ented

Action Plan fo r Incomp lete Op eration

S.N. Defects Description Model Action T aken Resp Person PDC

Electrical cable connection not done.

LPT3118 T C

A checksheet for all electrical connection in 3118 has been m ade so that no Sankalp electrical connection could be m issed. After fitm ent of tyre the operator is to confirm the stem v alv e position by putting yellow paint.

03.06.11

Stem Valv e position W rong

LPT3118 T C

Sankalp

Im plem ented

3 4

Silencer stopper ex cess gap Diesel Q ty less, engine not started.

LPT3118 T C LPT3118 T C

Feedback giv en to SQ A for analysis & Lobo Thom os counterm easure. Now the operator writes the actual filled qty in the register from the diesel dispenser. O perator awareness giv en. Eye clam p introduced. O perator awareness giv en. Rajat Im plem ented

5 6 7

Hyd pipe not clam ped from radiator bkt. Speedo cable layout wrong Silencer pipe clam p bkt taper

LPK2516 TC SA 1212 TC LPT 2518 TC

Rajat Rajat Rajat

Im plem ented Im plem ented Im plem ented

Check Sheet