Hello, for anyone here who doesnt know me, my name is Jose Daniel and I am one of the members

of the HP
program. Im going to show what I have been working this two weeks in the Quality department. There are two
projects: one of them is called Improving the control of 3D series measurements in KG 2011, which Im going to
present in English language. On the other hand, the project Reduccin de las reclamaciones de cliente en KG 2011 ,
I am going to present in Spanish language.

Lets get started with the first one. The document that have you received is an A3, where I follow the PDCA cycle to
carry out my project.

Background

Line 1 of 2011 KG cylinder block works like a two piece flow transfer line. To check that all elements mechanised
are between the tolerances that our main costumer order us, we measure the cylinder block in a 3D coordinate-
measuring machine. The best situation in these kind of lines is to measure the cylinder block in the end of the line,
where the piece has become a finished good, thereby we could check all the elements in one measurement.

Current condition

This figure shows the different 3D series measurements flows. Now, we measure the pieces by the operations that
are assigned in each machine. The frequency of that measurements, are set in I-4032. Operations five until thirty,
must be measured twice a week. Operation sixty four times a week, and operation 80 seven times a week. The total
number of measurements per week is 19. In each measurement it is necessary to clean the piece an take it to
Metrology. When the measurement is finished, the cylinder block is given back to the corresponding machine

As a result, this situation impact on the next indicators:

Security
o Transports
o Handling pieces: the quantity of movement that is it necessary to do to measure the piece totally.
o Pieces out of manufacturing flow
o Measurements flow: A01/A02, A1/A2
o Service: CMM saturation. We have two machines to make 3D measurements. Leitz an Crysta

All of this cause that we spend much time to measure pieces during the week.

Goals

Measure the al mechanised elements of the cylinder block improving the next indicators: bla, bla, bla, bla. And
therefore, we take time away of the 3d series measurements.

Analysis

In the next analysis tree, I try to find out the root cause of the problems that Ive said previously. There are 4 main
causes that stop us to achieve our goals.

1- There are elements we couldnt measure due to manufacturing process: For example, when the bearing cap
is assembled in the cylinder block, it is impossible to measure that drills.
2- 3D measurement programs have been made to measure by position
3- There are different workholdings to each position
4- There is an important limitation to measure in CMM Crysta. The probes only can measure angles from 7.5 to
7.5 intervals