Kaizen Event PDF

KAIZEN Event On
TO ELIMINATE WINDOW WINDING

HARD PROBLEM
www.ebz-gmbh.de
At BIW 1C Shop Uttarakhand
FROM 25.06.2012 to 29.06.2012
KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C
Objective & Target
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.
Kaizen Event Team Members
PANKAJ (QUALITY)
SUHAS (MQA)
(DY. LEADER)
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SANJAY KUMAR
(MENTOR ) SANJEEV KUMAR
RAKESH JOSHI (LEADER)
VARTIKA BISHT (KPO)
SHASHANK (KPO TRAINEE)
SUVIT(KPO TRAINEE)
SANDEEP KUMAR (MFQ)
Kaizen Event Opening Ceremony KAIZEN EVENT FLOW

MORNING MEETING REVIEW MEETING
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GEMBA VISIT
Guidance by Senior Mgt.
DATA COLLECTION
DATA COLLECTION
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PROBLEM STATUS
PROBLEM STATUS
55%
FREQUENCY(%)
60% 50% 40% 30% 20% 10% 0%
45%
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Series1
RH DOOR DEFECTS
LH DOOR
TARGET
40% 40% 35% 30%
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FREQUENCY
25% 20% 15% 10% 5% 0% BEFORE WINDOW WINDING HARD AFTER 5%
5W 1H ANALYISIS
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CAUSE & EFFECT DIAGRAM
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WHY WHY ANALYSIS
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Bending in Glass guide channel
Bending in Glass guide channel in edges-100%
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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.
Spot welding machine
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
Glass guide channel/bkt Width uneven
Bkt width uneven
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WHY WHY ANALYSIS
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KAIZEN DONE
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
To check the glass guide channel gap
Checked the lot after implementing the gauge, no variation is found .
Before Kaizen
After Kaizen
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Gauge for measuring the glass channel gap.
KAIZEN DONE
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
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.
Storage area of glass guide channel
Before Kaizen
After Kaizen
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Loosely placed glass guide channels
Trolley is made for placing the loose glass guide channels to avoid deformation
Difference in Sash Gap
Difference in sash gap
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Uneven gap 14.3-16 mm

WHY WHY ANALYSIS
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KAIZEN DONE
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
Glass Guide channel assembly fixture
Before Kaizen
After Kaizen
Gun guide provided Gun guide is provided for rigid support to glass channel
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BRACKET SHIFTING
Bkt Shifting, leading to mismatch of glass guide channel with Bkt
Glass movement is www.ebz-gmbh.de

restricted due to misalignment and mismatching of the sash profile and channel profile. Both profiles should match each other to obtain smooth motion
KAIZEN DONE
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
Matching of glass guide channel
Before Kaizen
Gauge is made for After Kaizen
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matching the GRM bkt & Glass guide channel in TCF
No gauge was present, earlier
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
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.
Spot Welding m/c
Before Kaizen
After Kaizen
Electrode tips are changed Filing is done before starting the m/c according to provided schedule
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Weird electrode providing oversize spots after welding
KAIZEN DONE
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
Fitment of glass guide channel
Before Kaizen
After Kaizen
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ONE POINT LESSON SHEET
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ONE POINT LESSON SHEET
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Activities Done In BIW
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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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TOTAL KAIZEN IDENTIFIED =14 COMPLETED = 10 INPROCESS=04
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
Target Achieved 95% (To reduce DPV)
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Result OF RH Door Glass Hard

45% 50%
Frequency(%)
40% 30% 20% 10% 0% Before event Target Defects Achieved 5% 6%
Target Achieved 92% (To reduce DPV)

Before event Target Achieved

Kaizen Event PDF

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KAIZEN Event On

TO ELIMINATE WINDOW WINDING

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

Objective & Target

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

Kaizen Event Team Members

(MENTOR ) SANJEEV KUMAR

RAKESH JOSHI (LEADER)

VARTIKA BISHT (KPO)

SHASHANK (KPO TRAINEE)

SANDEEP KUMAR (MFQ)

Kaizen Event Opening Ceremony KAIZEN EVENT FLOW

Guidance by Senior Mgt.

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

60% 50% 40% 30% 20% 10% 0%

25% 20% 15% 10% 5% 0% BEFORE WINDOW WINDING HARD AFTER 5%

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

CAUSE & EFFECT DIAGRAM

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

WHY WHY ANALYSIS

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

Bending in Glass guide channel

Bending in Glass guide channel in edges-100%

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

Spot welding machine

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

Glass guide channel/bkt Width uneven

Bkt width uneven

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

WHY WHY ANALYSIS

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

To check the glass guide channel gap

Checked the lot after implementing the gauge, no variation is found .

Gauge for measuring the glass channel gap.

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

Storage area of glass guide channel

Loosely placed glass guide channels

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

Difference in Sash Gap

Difference in sash gap

Uneven gap 14.3-16 mm

WHY WHY ANALYSIS

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

Glass Guide channel assembly fixture

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

Bkt Shifting, leading to mismatch of glass guide channel with Bkt

Glass movement is www.ebz-gmbh.de

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

Matching of glass guide channel

Gauge is made for After Kaizen

matching the GRM bkt & Glass guide channel in TCF

No gauge was present, earlier

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

Spot Welding m/c

Weird electrode providing oversize spots after welding

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

Fitment of glass guide channel

KPO/UKE304/Sanjay Kumar Window winding hard Project @ BIW 1C

ONE POINT LESSON SHEET