OBJECTIVE
(1) To validate all child parts. (2) To Establish standard work sheet. (3) To Identify quality check points. (4) To validate all process stage wise.
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TARGET : To eliminate the door glass movement hard defect from TCF. To minimize the rework downtime loss in Line for glass hard. To maintain proper sash gap for smooth movement of glass from BIW end.
PANKAJ (QUALITY)
SUHAS (MQA)
(DY. LEADER)
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SANJAY KUMAR
SUVIT(KPO TRAINEE)
KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C
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GEMBA VISIT
DATA COLLECTION
DATA COLLECTION
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PROBLEM STATUS
PROBLEM STATUS
55%
FREQUENCY(%)
45%
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Series1
RH DOOR DEFECTS
KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C
LH DOOR
TARGET
40% 40% 35% 30%
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FREQUENCY
5W 1H ANALYISIS
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KAIZEN DONE
Operation/Machine Problem
Earlier C type gun is used for providing the spot welding at the edges of the glass channel which due to striking with channel provides the bending at edges.
Measure Taken
Now X type gun is used at the edges to prevent the bending of the channel
Results
Now no bending profile is observed at the edges.
Before Kaizen
After Kaizen
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Now X type gun is used to prevent the bending of glass channel bending at edges
Earlier C type gun is used for providing spot welding on the edges of Glass guide channel
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KAIZEN DONE
Operation/Machine Problem
No gauge is present at supplier end for measuring the thickness of glass guide channel after fitment & before delivering to TCF.
Measure Taken
A gauge is prepared of 17mm for checking the gap, & trained the operators at supplier end for using the same.
Results
Before Kaizen
After Kaizen
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KAIZEN DONE
Operation/Machine Problem
Earlier the Mylor used to clamp the glass guide channels strike with the channel & creates bending profile onto it.
Measure Taken
Shim were removed from the Mylor & adjusted the proper difference for clamping the glass guide channel.
Results
Now glass guide channel doesnt bend during Mylor clamping.
Before Kaizen
After Kaizen
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KAIZEN DONE
Operation/Machine Problem
Earlier after receiving parts glass guide channel) supplier used to store that part in carton box, thus its profile varies in transferring & placing the loosely in ground during fitment.
Measure Taken
Arranged a trolley & keeping in view the profile of channel special rods were welded, as shown. Now the channels are placed in this trolley & carried from store to workplace..
Results
No deformation is observed during fitment now, & parts were properly stored & fitted in line.
Before Kaizen
After Kaizen
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Trolley is made for placing the loose glass guide channels to avoid deformation
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KAIZEN DONE
Operation/Machine Problem
No gun guide is present thereby glass guide channel during clamping slips away from its location & creates sash gap.
Measure Taken
Prepared a gauge for holding the Glass guide channel & GRM bkt to avoid mismatching.
Results
Now the glass channel & GRM bkt are properly matched for smooth running of glass
Before Kaizen
After Kaizen
Gun guide provided Gun guide is provided for rigid support to glass channel
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BRACKET SHIFTING
KAIZEN DONE
Operation/Machine Problem
No gauge is present for matching the glass guide channel with GRM bkt, thus mismatching of both occurs while glass movement.
Measure Taken
Prepared a gauge for holding the Glass guide channel & GRM bkt to avoid mismatching.
Results
Now the glass channel & GRM bkt are properly matched for smooth running of glass
Before Kaizen
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Rod is provided with gauge to prevent the motion of Bkt & Glass guide channel
BURR
EXCESS BURR SASH & GLASS GUIDE CHANNEL POSITION MISMATCH
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Burrs in the channel and sash result into reduction of effective GRM gap
KAIZEN DONE
Operation/Machine Problem
Spot welding m/c electrodes tip were found to be weared,thereby spots created were of abnormal size.
Measure Taken
We have changed the electrodes tip of all the Spot welders & made a schedule checklist for daily checking the electrode before starting the m/c.
Results
Spots are now of proper dimension & are not generating the dents as seen earlier.
Before Kaizen
After Kaizen
Electrode tips are changed Filing is done before starting the m/c according to provided schedule
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KAIZEN DONE
Operation/Machine Problem
Earlier no gauge is available in BIW for checking the sash gap & channel gap thus variation in gap is received at TCF.
Measure Taken
Gauge is provided of 17mm thickness in line & every vehicle door is checked for gap variation before sending to paint shop.
Results
Variation is minimised in TCF
Before Kaizen
After Kaizen
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Trial of window winding hard done at BIW end , keeping in view all the improvements done in house & supplier end
KAIZEN NEWSPAPER
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RESULT
Re sult of LH Door Glass Hard
55% 60% 50% 40% Frequency(% ) 30% 20% 10% 0% Before event Target Defects Achieved 5% 8% Before event Target Achieved
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Frequency(%)