Quality Circle Training

Manas Ranjan Parida ( QA Head – North )

❑ QUALITY CIRCLE JOURNEY STARTS -3 YEARS BACK WITH 1 TEAM
–( SANKALP) CII Competition
❑ CULTURE CREATED – 12 TEAMS ( INCLUDING PWD)

Every one can follow 12

Steps & do
Improvements…..!!!!!!
EXAMPLES FOR BETTER
UNDERSTANDING OF 12
STEPS….!!!!!
 WELCOME
Defect free, Life long products for 2 Wheelers

To
Quality Circle Competition

Team - प्रगति

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❑ Company Profile :- Spark Minda ([Link])
➢ Company & Product over view
Over view
• Business started in 1982
• ISO 9001 :2015
• Greater Noida • IATF 16949 Certified
• Haridwar • Total employees= 975No’s
• Pithampur

North Zone
Main Product is wire Harness

• Pune: II
West Zone
• Pune: I
• Murbad

South Zone

• Pillaipakkam (Chennai)
• Mysore
• Hosur

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❑ Major customers of Spark Minda ([Link])

2 Wheelers segment
Major Customers of Minda Corp Ltd- Gnoida

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❑ Manufacturing Capabilities at Spark Minda ([Link])

State of the art Machines and Equipment's for Wiring Harness operations

• Cutting & Crimping Cutting • Conveyor Assembly

Machines with Seal Insertion • Flexible line
• Fully & Semi Automatic • Dedicated Lines

100% end of line checking for

• Electrical continuity of wires
• Terminal Backout
• Inter-connection short circuit
• Presence of fuse, relays & diodes
• Water proofing testing

Schunk Ultrasonic Joint Welding Machine Automatic Seal Insertion

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❑ Team “प्रगति” Introduction

Team Name : “प्रगति ”

Team
Theme : Reduced Molding defect in
प्रगति
semi auto machines
Department : Quality Manas Ranjan
Mentor- Manager QA 15 Yrs

Working Area : LPC line

Circle formation date : 02 Mar 2023

Meeting Day : Monday to Saturday Vandana Kumari Team leader

- QA 5 Yrs

Meeting Time : 1 PM ~ 4:00 PM

Meeting Place : Training room

Attendance adherence : 95% Geeta Kumar Team

Member
Pankaj Kumar Team
Member
Dharmpal Team
Member
PDI- 3 years Production - 3 yrs Production – 1.5 yrs
Target is Zero defect in next 3 months
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❑ Activity Timing chart
Month Mar-23 Apr-23 May-23
[Link] Planned Activities = Plan
Week Wk-1 Wk-2 Wk-3 Wk-4 Wk-1 Wk-2 Wk-3 Wk-4 Wk-1 Wk-2 Wk-3 Wk-4
Plan
1 Identify the Problems
Actual = Done
Plan Slight delay of 07 days due to
2 Selection of Problem
Actual Holi Holiday

Plan
3 Define the Problem
Actual
Plan
4 Analyze the Problem
Actual
Identification Of Plan
5 Potential Cause &
validation Actual
Plan
6 Root Cause Analysis
Actual
Plan
7 Data Analysis
Actual
Plan
8 Developing Solution
Actual
Plan
9 Foreseeing Resistance
Actual
Plan
10 Trial Implementation
Actual
Plan
11 Regular Implementation
Actual
Plan
12 Follow up & Reviews
Actual
NOTE:- There is delay in activity due to “Holi holiday” but we manage with in next time frame
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STEP 1. Identification of Problems
➢ Brain storming on current Problems / Voice of customer/ Voice of Business

▪ Understanding the Current Situation at End of Line rejection at semi auto machines.
Customer complain

Month Wise Issues at EOL Data

445

440
440

435
435
432
Parts in No's

430
430 430 ▪ Understanding the
428
current PPM at EOL
425 ▪ Target is to “Reduce EOL
425
422
Rejection up to 50%”
▪ For Further stratification
420 of EOL defects is refer
next slide
415

410
July.22 Aug.22 Sep'22 Oct'22 Nov'22 Dec'22 Jan'23 Feb'23
Qty in No's 440 430 435 432 430 428 425 422
STEP 1. Identification of Problems
➢ Brain storming on current Problems / Voice of customer/ Voice of Business

▪ Understanding the Current Situation at End of Line rejection at semi auto machines.
QTY. Cumm % Pareto trend for EOL Data collection for last 3 months
98 100 100 100
96
95
450 92
90 90
86
400 82 80
76
350 70
69

62
▪ Terminal back out
300 60 contribute 50% of the total
250 Selected for defect as observed from
50 50
210
Analysis Pareto trend
200 40 ▪ Therefore Terminal back
out is selected for
150 30 analysis and
improvement
100 20
▪ Further stratification of
53 terminal back out on next
50 30 27 26
10
17 15 12 9 8 8
slides
5 2
0 0
Short wire cut copper out Heat Sealing Hst Ng High core Terminal Terminal Terminal Tapping Mouth Wrong wire Wire colour
molding NG Bend Lock Fold Damage Open Open NG
STEP 3. Define the Problem
➢ Defect Description & Information
▪ Defect Description & Information

Customer : NA
Part Name : Wire Harness
MCL Part No. : 471403001700
Customer Part No : 471403001700
Complaint reported : Short molding
Function name : Harness wire

Complaint Type : Functionally NG because

short molding leads to contamination in wire
NG Parts
Area of Detection : During Inspection

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STEP 3. Define the Problem

Contamination inside the wires lead to

dissatisfaction to User

Contamination inside the wires lead to

Vehicle starting problem

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STEP 4. Analyze the problem Short molding material catch

➢ Process flow diagram during Inspection

Short mold
material received

Material Receiving & Cutting Stripping and

Material inspection Storage Middle Splicing Joint Crimping
inspection crimping

Final Inspection Cable Tie Cutting and Sub Assy(Terminal and

Circuit Testing Final Assy Material processing cell
length verification Connector fitment)

Finish Goods

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STEP [Link] of Potential causes & validation
➢ Fish bone diagram

Measurement Man Material

Short molding - Loading weight Not set as per

specification ( loading weight more)- -Not
significant
.

Short molding - Loading weight Not set as per

specification ( loading weight less)- significant
.

▪ Short molding-– Bumping Not set as per

specification -Not significant

Short Molding -Mold temperature Not set as per

specification lower limit-Not significant
.

Short molding- , M/c. Pressure Not set as

Short Molding -Mold temperature Not set as
per specification - Not significant
per specification Higher limit-Not significant

Mother nature Machine Method

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5.1: Identification of Potential causes & validation
➢ 4M = Material
❑ Verification – 1:- Short Molding -Mold temperature Not set as per specification at Higher limit

Over Curing part produced

Moulding Temp Plate Standard.= 230 °c± 10° c

Moulding Temp Plate Set = 248 °c
Result:- From simulation trial we came to know that if we increase or decrease Mold temperature only curing will effect but it will not
contribute in short moulding.
Existing Controls:-
1).POKAYOKE installed inside the Machine if temperature goes more that 240 Degree
Cel “Alarm” will raised. Conclusion : Not a Significant Cause
2). Level 3 skilled manpower used for molding process

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5.1: Identification of Potential causes & validation
➢ 4M = Material
❑ Verification –2:- Short Molding -Mold temperature Not set as per specification at lower limit

Part not cured properly

Moulding Temp Plate Standard.= 230 °c± 10° c

Moulding Temp Plate Set = 219 °c
Result:- From simulation trial we came to know that if we increase or decrease Mold temperature only curing will effect but it will not
contribute in short moulding.
Existing Controls:-
1).POKAYOKE installed inside the Machine if temperature goes more that 240 Degree
Cel “Alarm” will raised. Conclusion : Not a Significant Cause
2). Level 3 skilled manpower used for molding process

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5.1: Identification of Potential causes & validation
➢ 4M = Material
❑ Verification –3:- Short Molding - Bumping Not done properly

AIR Bubbles trapped on Top

portion of cover

As per Standard bumping will done Manually = 3 Times

If Bumping not done then Air bubbles get trapped on surface of cover

Result:- From simulation trial we came to know that if we do not perform Bumping then “Air bubbles” get trapped on top portion of cover but it
will not contribute in short moulding.

Existing Controls:-
1). Bumping done 03 times as per work instruction
2). Level 3 skilled manpower used for molding process Conclusion : Not a Significant Cause

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5.1: Identification of Potential causes & validation
➢ 4M = Material
❑ Verification –4:- Short Molding - M/c. Pressure Not set as per specification

Flashes Thickness less & seems

Flashes Thickness more over cured
M/c. Pressure standard= 1200 -1800 PSI M/c. Pressure standard= 1200 -1800 PSI
M/c Pressure set = 900 PSI M/c Pressure set = 2000 PSI

Result:- From simulation trial we came to know that if we increase or decrease pressure ,”Only flashes thickness will vary”

Existing Controls:-
1). Pressure is Freeze/set during “first piece approval” & regular monitoring done by
Quality & production team Conclusion : Not a Significant Cause
2). Level 3 skilled manpower used for molding process

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5.1: Identification of Potential causes & validation
➢ 4M = Material
❑ Verification –5:- Short Molding - Loading weight Not set as per specification ( Loading weight More)

Flashes Increased

Loading weight 110 ± 10 gm

Actual = 129 gm
.
Result:- From simulation trial we came to know that if we increase Loading weight of Compound
Extra material will flow out side and increase Flashes

Existing Controls:-
1). Manual control & operator dependent
2). Level 3 skilled manpower used for molding process
Conclusion : Not a Significant Cause

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5.1: Identification of Potential causes & validation
➢ 4M = Material
❑ Verification –6:- Short Molding - Loading weight Not set as per specification ( Loading weight less)

Short molding

Loading weight 110 ± 10 gm

Actual = 94 gm
.
Result:- From simulation trial we came to know that if we reduce Loading weight of Compound
Short molding parts will generated

Existing Controls:-
1). Manual control & operator dependent
2). Level 3 skilled manpower used for molding process Conclusion : Significant Cause

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STEP 6 : Root Cause analysis

❖ Root Cause Analysis. (Occurrence)

Short molding found in Cover:-
Why 1 :- Short mo

Why 2 :- Because fuse box terminal not lock properly in connector

Why 3:- Because fuse box terminal partially Inserted on connector
Why 4:- Because fuse box terminal lock Press
Why 5:- Because fuse box terminal get lock press while crimping if Applicator Anvil not a
proper terminal lock shape

FINAL CONCLUSION :–
Reason 1 - Because Terminal Lock press in case Crimping anvil is not properly Grind by Applicator Maintenance Technician

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STEP 7: Data Analysis
➢ Detail description about exact issue further course of action
Explanation

During investigation we found that Terminal lock struck Terminal Lock press in case Crimping anvil is not properly
with Anvil applicator therefore terminal lock get press Grind
(New Applicator Anvil needs to be grind before used )

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STEP 8: Developing Solution

Actions taken:– MIS-F & Displayed on line Training & Awareness given to Operators.
MCL
Sr. No. location Containment Action Evidence Photo Quantity Result Judgement

500 pcs check at MCL

MCL (1.1) Training Provided to All part found
1 OK = 500 Pcs
Plant Operators & Inspectors. OK
NG = 0 Pcs

(2.1) Check point added &

Displayed. Better
MCL (2.2) All suspect stock WIP, FG Communication
2
Plant at MCL Store is checked & 100% of Defect
marking start.

(3.1) Breakdown/Preventive maintenance to be update with Check

MCL point for Applicator Crimping Anvil Grinding . Analysis in
3 -
Plant Slide no.
Details in next slides

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STEP 9. Foreseeing Resistance

Before condition After condition

Conclusion:-
▪ Applicator Breakdown/Preventive maintenance to be update with Check point for Applicator Crimping Anvil Grinding
▪ Grind Crimping anvil used to avoid the lock press

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STEP 10. Trial Implementation

Trial done on Improved part – 22000 No’s Qty

Date Offer OK Qty
(After Improvement parts)
6000 11.08.23 5000 5000
5000
12.08.23 3500 3500
Qty in No’s

4000

18.08.23 3000 3000

3000

2000 25.08.23 3000 3000

1000
PERFECT RESULT
26.08.23 2800 2800
0
11.08.23 12.08.23 18.08.23 25.08.23 26.08.23 27.08.23 28.08.23
27.08.23 2500 2500
Qty Offer
Series1 5000 3500 3000 3000 2800 2500 2200
Series2
OK Qty 5000 3500 3000 3000 2800 2500 2200 28.08.23 2200 2200

Note:-
After Anvil Modification parts 22000 No’s run on line and
found “Zero terminal lock press issues”

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STEP 11. Regular Implementation

[Link]/Preventive maintenance to be update with Check point on sheet

Status - Done
New Applicator Anvil used after Grinding

Grind New Applicator to avoid the terminal

Action taken :– Check point added in Breakdown /Preventive lock press
maintenance sheet for Applicator Anvil grinding

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STEP 11. Regular Implementation
3. Control Plan updated for Back out issue Status - Done
4. FMEA revised for Back out issue Status - Done

■ Horizontal Deployment .
• There is Similar type of fuse box Terminal used for All model
• (AAE,K74,KZK etc)

■ Tools Used.
Brain storming Pareto Chart Flow chart Fish bone dig Why Why analysis

Slide- Slide- Slide- Slide- Slide-

Bar chart

Slide-

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STEP 12. Follow Ups & Review

500
Month Wise Issues at In -house 50 % Reduction
460 458 450 442 440
450 430 435 432 430 428 425 422 No fuse box terminal
400 back out issue reported

350
Action Taken
Number of Cases

300
250
200
150
145
120
PERFECT RESULT
115
95
100
50
0
April.2 May.2 June.2
Mar.22 July.22 Aug.22 Sep'22 Oct'22 Nov'22 Dec'22 Jan'23 Feb'23 Mar'23 Apr'23 May'23 Jun'23
2 2 2
Final Output:-
No of Cases 460 458 450 442 440 430 435 432 430 428 425 422 145 120 115 95

After Anvil Modification No terminal lock press case

reported from HMCL line (In-house )
OK

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STEP 12. Follow Ups & Review

■ Benefits.

Reduction in Reworking Cost High Morale

TANGIABLE Rreduction in Manpower Cost
INTANGIABLE Less Fatigue
BENEFITS Quality Improvement BENEFITS
Decline in Cost of Poor Quality Team Integrity

■ Our Thought : Slogan.

“It’s not in the stars to hold our destiny but in ourselves”.

अपने भाग्य की रे खाएं तििार ं के भर िे नही ं बल्कि खुद के भर िे पर ह नी चातहए

■ Q & A.

Your feedback is most welcome

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Thank you

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