spring noise copy

D M A I CDefine Measure Analyze Improve ControlDefineD

Measure

MAnalyze

AImprove

IControl

C

D M A I CDefine Measure Analyze Improve ControlDefineD

D M A I CDefine Measure Analyze Improve Control

NISSAN booster assy line

Front shell shear riveting

Front shell Spring pri-assy

Front shell & diaphragm assy

Collar height setting

Booster assyBrakes “OFF” testing

Brakes “ON” testing

mBA actuation test

Booster crimping

Output rod height setting

Booster & TMC coupling

Booster & TMC coupling

Booster & TMC Duplex test

Clevis height setting

Final Inspection

Process flowDefineD


Rework

InspectionWarranty

Rejects

Lost sales

Late delivery

Engineering change orders

Long cycle times

Expediting costs

Excess inventory

Hidden Costs

Visible Costs

Lost Customer Loyalty

More Set-ups

Time value of money

Working Capital allocations

Excessive MaterialOrders/Planning

Recode

(less obvious)

COPQ - Iceberg Measure

M


Spring noise

Spring rubbing

Improper seating

Improper assy

WHY WHY analysis Analyze

A


Improper assy of spring

MachineMaterial

OperatorEnvironment

Training

Method

Spring dimension

Spring Bend

Improper clampclamp device

Prong dimension Pressure variation

Analyze

AAnalyze Phase


NISSAN booster assy line

Front shell shear riveting

Front shell Spring pri-assy

Front shell & diaphragm assy

Collar height setting

Booster assy

Process flow

PHOTOPHOTO

Analyze

A


Any abnormality in assy station ?

Spring NOT releasing after pressing PB

Spring released earlier before pressing PB

Spring adjusted manually by screw driver for proper seating of spring in retainer

Analyze

AAnalyze Phase


Spring adjusting manually by screw driver for proper seating in valve body

Spring improper seating

Analyze

AAnalyze Phase


Clamping Prong dimensions verified

Spring Concentricity verified

Observations

Why 100% samples is not getting rejected ?

Why 100% samples is not getting OK?

Analyze

AAnalyze Phase


Spring pre-assy fixture are identified and spring seating verified after assy.

Analyze

AAnalyze Phase


Proper seating of spring in valve body observed in pre-assy fixture -3.

What's the mismatch between Fixture-3 & Fixture -1,2,4 ?

Analyze

AAnalyze Phase


Prongs

Front shell

Fixture -1,2,4 Fixture -3

FIXTURE MODEL

Fixture bottom

Spacer

GAP

Analyze

AAnalyze Phase


θ

GAP

Front shell

Spring

Prongs

Spring locator no. 1, 2, 4

Spring deformed

Analyze

AAnalyze Phase

D M A I CDefine Measure Analyze Improve ControlImprove

I

Recommendations for improving the process:

• All 4 Fixtures to be replaced identically like fixture-3

Implement the above recommendations and run additional samples to verify results.

Improve Phase

D M A I CDefine Measure Analyze Improve ControlControl

C

Recommended controls :

• Implement color coding for NISSAN fixture.

Control Phase

spring noise copy

Automotive