Reduce Defect Accuracy IMV 5 Model by Eliminating Problem NTC

Stamping Part 67189-0K030 Reinforcement Back Door Stay

Name

: Reza Rahmaputra

Date Of Entry

: 02 September 2013

No.Reg

: 1324394

Department

: Vehicle Quality Prod. Engineering

Section

: Vehicle Quality and Planning

TMMIN VISION 2014

DIVISION KPI

To be the Best and the Most

Flexible in Asia Pasific

Zero Defect Outflow To

TMMIN

A. TMMIN PART CHAIN MAP

->

Project Management & Control

Toling Progress & Control

Tooling Technical Support

Quality & Accuracy Approval

Quality & Accuracy Achievement

->

No

Item

Accuracy
Target (%)

Confirmation
Vehicle (CV)

95

Soukaku (SKK)

2
3

Goshi (1W)

100

Accuracy Achievements Target

100
90
80
70
60

85 86

76

10-12

1-3

TOOLING KICK OFF

4-6

7-9

10-12

1-3

4-6

Goshi

Soukaku

7-9

Mass Product
Trial ( MPT)

10-12

Qty Defect

100

MPV

112

Rank
17

CV'Feb

Week IV' April Soukaku

59

0
Defect Surface Defect Accuracy

Defect Spot
Weld

16

(14 DA)

12
8

CV

Accuracy
(Trimline,Aspec
Surface, Hole
Position)

Part Surface

Rank

No Defect Outflow

Rank

Week IV'April Soukaku

Provide Good Quality, Good Process,

Achieve Production Volume & No Delay

Current Condition

By Where

Problem

59 DA at NTC

59 Defect Accuracy on
CV Activity (February
2014)

By Category Part
35 DA at
Stamping Part

By Part Number
18 DA at R/F Back door
Stay (67189-0K030)

Items

Qty Problem

Trimline

Aspec Surface

Hole Position

Appearance

Total

0 DA at Others
Supplier

Pareto Diagram

16

24 DA at Sub Assy
Part

10 DA at R/F Quarter wheel

House (61671-0K020)

7 DA at Hood S/A, Hood

Lock (53831-0K050)

12
18

10

0
61671-0K020

53831-0K050

13

18

67189-0K030 R/F Back Door Stay

Part

Trim Pierce 1
Dies NG

Gap

Fitting Panel
NG

Radius Panel x Radius

Dies Unmatch

Dies Process Trim

Pierce 1 Repaired
(Setting)

February
II
IV

PIC

March
II III IV

April
II III IV

Trimline Plus Ilustration

Act : Radius Panel < Radius Dies

Std : Radius Panel = Radius Dies

May
II III IV

AA
SURFACE
(-)
STD : 0.5
(+)
ACT : +0.8

Part
(-)

BA

June
II III IV

Schedule
July
II III IV

Aug
II III IV

: STD
: ACT

Lower
Dies

TRIMLINE PLUS
STD : 0.7
ACT : +1.5

Sept
II III IV

Oct
II III IV

Nov
II III IV

Dec
II III IV

Die Repair 3

Trial and Repair 2

Trial and Repair 3

Judgment

Soukaku
Activity

Judgment

Result and Feedback

No SOP For Panel

Fitting

Upper
Dies

STOPPER
PAD

Accuracy Achieved 96%

and SOP Implemented

Defect Accuracy Investigation

Die Repair 2

NTC Dies
Maintenance
(Baharudin),
VQPE (Reza)

: STD
: ACT

Lower

RC #2

Result

SOP Compiling and Approval

Implementation SOP

Make SOP For Fitting

Panel

VQPE
(Reza),NTC
(Budi)
Result and Feedback

. Aspec Surface Repair

Upper
Dies

Upper
Dies

*Defect Accuracy Related :

Upper
Dies

STOPPER
PAD

Lower Dies
LOWER

Panel Moved When

Trim Pierce 1
Process

Spec Material
Equal with
standard

Radius Panel x
Radius Dies
Unmatch

Countermeasure

. Trimline Minus Repair

Panel Not
Fitting

Machine

()

Defect Accuracy IMV 5 Model 59 DA on CV

Activity (February 2014)

Panel Moved

(+)

( and )

Defect Accuracy IMV 5 Model 59 DA on CV Activity

(February 2014)

Trimline Minus Ilustration (, and )

Panel not Fitting Ilustration ()

Material

Inefficiently
Fitting Panel

Root Cause

Rank

GAP

STEP 2 BREAKDOWN THE PROBLEM

1W

DIES

MP
Experience
Level 3

* DA = Defect Accuracy

Defect Accuracy IMV 5 Model 0 DA on CV Activity

(February 2014)

Ultimate Goal

STEP 5 DEVELOP COUNTERMEASURE AND COUNTERMEASURE

Spot
Weld

Burry,Marking,Kaji
ri and Emboss

R Panel < R Dies

Notes :
MP : Man Power
SOP : Standard of Procedure
NG : Not Good
RC : Root Cause

STEP 4

Reduce 14 DA and
Accuracy Achievement 95%
From NTC Stamping Part
Reinforcement Back Door
Stay (67189-0K030) in
Trim Pierce 1 process until
week IV April 2014

Defect Decrease Target

18

20

RC #1

Ideal Condition

STEP 1 CLARIFY THE PROBLEM

Defect Accuracy

Problem Founded

1W

No SOP For
Panel Fitting

STEP 3

STEP 2

Check by
Proto and
Designer

Key Point :

Methods

Form Ability
(Crack,
Shiwa and
Nobi)

Proto Check

Check by
Inspector

Cam Pierce

Man

CV FEEDBACK AND REPAIR

STEP 1

Rank

67189-0K030

Flange

18 Defect Accuracy From NTC Stamping

Part Reinforcement Back Door Stay
(67189-0K030) in Trim Pierce 1 Process

All Accuracy CV Part

Achieve by TMC Proto
with Feedback : Need
level Up and No
Handwork For Soukaku
(SKK) Activity.

F. STEP HOW TO REPAIR

Rank

y7

Cam Pierce

Actual

2015

CONFIRMATION
VEHICLE (CV)

E. CV PREPARATION PROBLEM FOUNDED

Inspection
Process

Target

2. Soukaku (SKK) is Trial Confirmation activity both press part and weld tooling.

Reza R.Putra

100

95

95

1. CV Preparation : All CV Part From Supplier Checked Quality and Accuracy Achievement by TMC Proto

20

Muh.Anhar K

STEP 3 SETTING TARGET

85

*Notes :

50

Trim Pierce
1

Forming

Before CV

2014

CV PREPARATION

150

Ndaru J

STEP 4 ROOTCAUSE ANALYSIS

7-9

FMC

Nicholas A

Cutting
Cutting

Lower
Dies

Lower
Dies

STANDARD OPERATION PROCEDURE (SOP)

NO : SOP-DB00-2301

PROCESS
PANEL FITTING

TANGGAL
: 30-04-2014
REVISI
: 0 KE
HALAMAN
: 1 dari 1

NO FAKTOR

Cutting
Cutting

Add
Weld
Add
Weld

. Making Procedure For

Fitting Part

Add
AddWeld
Weld

M
Q
Q
M
Q
Q
Q
Q
M
M
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q

LANGKAH KERJA
1.0 Ambil panel buat panel fitting
1.1 Taruh panel diatas die yang akan di panel fitting
1.2 Beri tanda pada panel dengan spidol cat
1.3 Bawa panel ke lokasi mesin plasma
1.4 Lobangi panel yang diberi tanda dengan spidol cat
1.5 Bawa panel dekat dienya yang mau di panel fitting
1.6 Ambil gerinda pada tempatnya
1.7 Rapikan hasil plasma dengan gerinda
1.8 Kembalikan gerinda pada tempatnya
1.9 Bersihkan panel dari kotoran
2.1 Ambil akaipaint dan kwas pada tempatnya
2.2 Oleskan panel bagian yang penting dengan akaipaint
2.3 Kembalikan akaipaint dan kwas pada tempatnya
2.4 Ambil tanah liat pada tempatnya
2.5 Perhatikan bagian yang penting
2.6 Taruh panel diatas die yang akan di panel fitting
2.7 Ketok panel dengan tangan atau tangkai kwas
2.8 Angkat panel
2.9 Panel taruh tempat yang aman
2.9a Ulangi step kerja no:1.9 hingga 2.9
2.9b Hingga bagian penting atarinya benar-benar rata
2.9c Gosok bagian atari
2.9d Sanding bagian-bagian yang kurang penting
2.9e Die selesai proses panel fitting

DEPT
SECT.
LINE

DISAHKAN

: TM
: DAT
: T/O

DIPERIKSA

DEPT. HEAD SECT. HEAD

HAL PENTING (KEY POINT)

-Ambil panel proses sebelumnya
-Perhatikan model panel terhadap Lwr die
-Tandai bagian panel yang bersentuhan
-Gunakan Dolly
-Gunakan mesin plasma untuk melobangi
-Gunakan Dolly dan taruh tempat yg aman
-Gunakan gerinda sesuai kebutuhan
-Panel sebelum di panel fitting harus rapi
-Taruh gerinda pada tempatnya
-Gunakan majun hingga bersih
-Campuran Akaipaint harus rata
-Oleskan panel yang bersentuhan dng model die
Taruh Akaipaint Pada tempatnya
-Tanah liat warna merah
-Beri tanah liat sedilit bagian yg penting/ kijun
-Panel jangan sampai rusak / penyok
-Ketok panel secara pelan pelan
-Angkat panel berdua apabila panel ukuran besar
-Gunakan cover
-Ulangi step kerja1.9 s/d 2.9
- Atarinya rata dan panel tidak labil/goyang
-Gunakan batu gosok #80,#120
-Gunakan gerinda sanding
Die siap Pad Awase

DIBUAT

LINE HEAD

ILUSTRASI
1

Part Forming
yang OK

: OK : NG

Point Check

OK
59

Defect Decrease Result

18
20
15
10
3
5
0

96

100

86

90

76.6

80
70

Before CV

CV'Feb Week IV'April

CV'Feb

Week IV'April

* Contributed to the Gap Condition : (15/59)*100%= 26% Reducing Defect

STEP 6 MONITORING RESULT

Before Repair

Accuracy Achievement
Accuracy (%)

IMV 5

Nandy J

Problem to Tackle:
18 Defect Accuracy from NTC Stamping Part Reinforcement Back Door Stay (67189-0K030) in Trim Pierce 1 Process

: Main
: Support

2013

LEVEL

Prepared by

Point of Occurence

D. PROJECT MILESTONE
MODEL

Checked by

C. QUALITY PERFORMANCE INDEX

TMMIN
Supplier
PUD VQPE

ITEM

Supplier

"0" Defect Outflow

B. PRODUCTION ENGINEERING ROLE

TMMIN

JOB RESPONSIBILITY
Part Accuracy and Quality
Management

Approved by

Stamping Process

Blanking

DEPT. KPI

Acknowledge

Case (Defect)

Division
: Prod.Eng Division
BACKGROUND

Flow Process:

Acknowledge

Case (Defect)

PT. TOYOTA MOTOR MANUFACTURING INDONESIA

PRODUCTION ENGINEERING DIVISION
VEHICLE QUALITY PRODUCTION ENGINEERING DEPT.

NG
18

Total : 77

Accuracy

76%

After Repair

: OK : NG

Point Check STEP 7 STANDARDIZATION

OK
74

NG
3

Total : 77

Accuracy

96%
No Handwork ( Full
Dies Output)

5W1H
Item

WHY

Panel Fitting No Mistake when

Procedure
fitting part

WHAT

WHEN

WHERE

WHO

HOW

SOP

Try out Activity

NTC Plant

Operator

Fitting Part
Confirmation

STEP 8 NEXT ACTION

>Follow Up Level Up Activity 67189-0K030 Until Soukaku Activity
>Reduce Defect Accuracy at Reinforcement Quarter Wheel House
0K020)

(61671-