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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
D M A I CDefine Measure Analyze Improve Control
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
D M A I CDefine Measure Analyze Improve Control
Spring noise
Spring rubbing
Improper seating
Improper assy
WHY WHY analysis Analyze
A
D M A I CDefine Measure Analyze Improve Control
Improper assy of spring
MachineMaterial
OperatorEnvironment
Training
Method
Spring dimension
Spring Bend
Improper clampclamp device
Prong dimension Pressure variation
Analyze
AAnalyze Phase
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 assy
Process flow
PHOTOPHOTO
Analyze
A
D M A I CDefine Measure Analyze Improve Control
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
D M A I CDefine Measure Analyze Improve Control
Spring adjusting manually by screw driver for proper seating in valve body
Spring improper seating
Analyze
AAnalyze Phase
D M A I CDefine Measure Analyze Improve Control
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
D M A I CDefine Measure Analyze Improve Control
Spring pre-assy fixture are identified and spring seating verified after assy.
Analyze
AAnalyze Phase
D M A I CDefine Measure Analyze Improve Control
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
D M A I CDefine Measure Analyze Improve Control
Prongs
Front shell
Fixture -1,2,4 Fixture -3
FIXTURE MODEL
Fixture bottom
Spacer
GAP
Analyze
AAnalyze Phase
D M A I CDefine Measure Analyze Improve Control
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