Case study

1. 1
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
PRESENTED BY: GOKUL.G

2. 2
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
OBJECTIVE : To contribute towards the improvement
and development of the organization by
enhancing its quality and output.

3. 3
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
INTRODUCTION
 Name of the Department : Drive Belt Pivot Pin
 Running Since : 1 March 2014
 Customer Details: LK Metrology, EMA, Argosy Road,
Castle Donington Derby DE74 2S4, United Kingdom.
No of Machines : 16 Turning Machines, 6 Milling Centers,
Grinding Machines.
No of Employes : 18

4. 4
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
Part Name : Drive Belt Pivot Pin
Part No : MLD0060A
Aim : To Reduce the stopping of the belt from pivoting.
Duration of Project : 3 Months (Start Date:03/03/2023 –End
Date:19/04/2023)
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
Problem Defination :

5. 5
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)

6. 6
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
Observation: 194
93
77
16 11
0
50
100
150
200
250
In
Nos
Characterstics
Top 5 Rejection of Dec 2022
MD Total length U/S
M9 Thread damaged Nogo ø7.03 Nogo ans
Angle 90° guage tight
457
88
31 27 12
0
100
200
300
400
500
In
nos
Characterstics
Top 5 Rejection of Jan 2023
MD Total length U/S ø4.49 Nogo ans M9 Thread damaged Nogo 4.49 Bore line
970
141
49 27
0
500
1000
1500
In
nos
Characterstics
Top 5 Rejection of Feb-2023
MD Total length U/S M9 Thread damaged Nogo ø4.49 Nogo ans

7. 7
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
Brain Storming Points:
Sl No Reason
1 Loose burrs on fixture.
2 Pre part loose burr stuck between reference face and
part.
3 Improper clamping of part on fixture.
4 During insert change.
5 Stopping the belt from pivoting.
6 Improper flow of coolant Through Chuck.
7 Improper setting of insert on tool holder.

8. 8
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
We have analysed the undercut that is not
achieving the R0.2 Max.
We are about to study the stopping of the belt
from pivoting under ICIR21522.
We have modified it and the only setting part was
checked and balance were checked visually.
We have modified the fixture.
Analysis:

9. 9
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
1.Only the setting part was checked for undercut and balanced were checked
visually
2. Usage of Ring Gauge to check for proper butting on the face.
Summary of Root Causes
On the parts, undercut was more on the outside diameter than the face
leaving a lip on the face.
Why: Only the setting part was checked for undercut.
Why: Visual Inspection
Why: Improper Training.
Counter Measure: The above corrective actions will be implemented horizontally on all similar parts.
WHY ? WHY ? ANALYSIS

10. 10
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
Category Supplier for quality & awarded “SHIP TO LINE” status for majority of our components. Cost
Effective Tailor Made Solutions.
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
In the process drawing only 0.2R Max was
shown at the intersection point ,Now we
have changed the process drawing : An
enlarged view is clearly showing undercut on
both face and diameter.
ACTION

11. 11
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
BEFORE AFTER (FIRST STAGE MODIFICATION)

12. 12
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
3D Model of Modified Fixture

13. 13
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
Check Sheet
Date : Unit : Nos
Part No / Name : K0923590SF05 - Roller Tappet Shell
Quantity Inspected Quantity OK Defect ( Dent on lever )
100 100 0
100 100 0
100 100 0
100 100 0
100 100 0
100 100 0
100 100 0
100 100 0
100 100 0
100 100 0
Total = 1000 1000 0
EFFECTIVNESS CHECK

14. 14
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
TOTAL LENGTH REJECTION

15. 15
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
• Customer complaint: PO21-11462-20 NOS
• Rejection of pivoting pin brought down to ‘0’ from 141.
• Productivity improved.
• Solution deployed horizontally to 2 Machines.
• Cost saving.
CONCLUSION

16. 16
SRI JAYACHAMARAJENDRA (GOVT) POLYTECHNIC
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)
DEPARTMENT OF MECHANICAL ENGINEERING (GEN)