QRQC- Quick Response To Quality

Control at Escorts Agri Machinery

Submitted byKshitij Bhakoo

ASU2012010100037
Btech mechanical
Apeejay Stya University

What is QRQC?
Quick Response Quality control is not only a quality control
tool and method for troubleshooting but also an innovative
concept in the field of global quality management.
QRQC integrates a simple and logical solution to a given
production or business operation problem within 24 hours
time and has applications in many different segments along
supply chains, including project management,
manufacturing, logistics and others.
QRQC focuses on quality control to ensure that any problem
is identified and isolated and that a solution is found and
implemented quickly and effectively.

QRQC is based on a Japanese concept known as San Gen Shugi,

it is a scientific method and concept of problem solving and analysis with farreaching applications.
SAN GEN SHUGI means "3 reals" in Japanese:
Gen-ba means "real place",
Go to the shop floor to understand the reality. This is a more effective method
than simply reading a report.
Gen-butsu means "real part",
Look at the real part or the real service provided and analyze it while focusing
on the facts.
Gen-jitsu means "real facts"
Present conclusions using real data for a better understanding of what is
actually happening in the field.

Now that weve discussed the origins of Quick Response Quality Control,
lets delve into the steps for implementation:

Step-1- Acknowledge the concern reportedThis is further divided into three partsCustomer voice/ ComplaintThe exact complaint/problem.
Sharp definition of the problem(5W-1H)A clearly defined problem is half solved, this step involves clearly defining the
problem in the form of 5WS and 1H i.e. where, when, why, what, who and how .

 Step-2- Immediate response given to the problem.

Step-3- Root cause analysisMain cause of the problem and its analysis.
It is done by Plan-Do-Check-Act (PDCA) is an iterative, four-step problemsolving process typically used in process improvement. It is also known as the
Deming cycle, Shewhart cycle, Deming wheel, or Plan-Do-Study-Act.

Step-4- Corrective ActionAs mentioned before San Gen Shugi is the foundation of QRQC based on data
collection to explain quality issues, quick response to take action and deep
analysis to assess effectiveness. Only after these steps are taken do we arrive at
permanent corrective action, this step is the corrective action taken or the
conclusion we get after the execution of above steps, corrective action should be
such, that it should avoid the re- occurrence of the problem.

Acknowledge the
concern reported

Step 2

QRQC

Corrective action
Step 4

Step 3

Root Cause Analysis

Step 1

Immediate
correction

Based on a very practical approach, starting from the field realities, the
establishment of the QRQC will allow:

The drastic reduction of the Quality problems

The development of the autonomy and responsibility of the production teams
. The development of efficient preventive actions.

QRQC Analysis of problems:

Rear plate bolt free

Standard size of the bolt used in rear plate:

28.19 mm
9.32 mm

Length- 28.19mm
Diameter- 9.32mm

Machining process involved:

There are three processes involved on the rear plate of C.T.
CleaningThe fixture on which the C.T. is placed is cleaned before placing the C.T. , It is an
important process because if cleaning is not done properly the it can lead to problems
in threading
Chamfercut away (a right-angled edge or corner) to make a symmetrical sloping edge, in the
holes made in the case transmission.

The tool shown above is used for this process.

TappingForming an internal screw thread in the hole by means of a tap .

The tool shown above is used for tapping.

After the above three processes, a gauge is used to check the taps and
threading.

Process sketch sheet of rear plate:

Standard position of all the drills and taps on the rear plate mentioned on the sheet.

QRQC Analysis of rear plate bolt free:

Step-1- Acknowledge the concern reported
Customer Voice/Complaint- Rear bolt free
Sharp definition of the problem(5W-1H)Rear plate bolt free, on 4th February 2016 at transmission
assembly line, QRQC analysis of the problem will throw some
light on the actual causes of the problem
Step-2- Immediate correction to the problem
Immediate response- C.T. kept aside for check
Thread plug gauge check
bolt size checked

Step-3- Root cause analysis

Root causeThe machining department theory- after the checks they found that
bolt diameter was undersize.
Bolt length was less.
While after the bolt size analysis test, they were found to be normal
Faulty operator- The operator performing the machining process on
the C.T. rear plate did not do the tapping and drilling
process properly, which resulted in poor threading
and gauge test also failed.

Step-4- Corrective Action

Corrective actionDrilling and tapping process should be done following the proper SOP.
Any slack attitude in the process will result in faulty threads.

Output Shim

Why is output shimming done?

Output shaft and main shaft are connected through bearings, Shimming is done to avoid
the bubbling of output shaft and main shaft, when output shaft
moves in high speed, can cause bubbling, to control the play of main shaft and output
shaft we follow a process called shimming.
Standard shimming value = 48 Thou-18 Thou.
If greater than 47 Thou the shim is high and if lower than 21 Thou the shim is low.
What happens when shim is not of standard value?
If shim is high then it might hamper the connection and the play between main
shaft and output shaft and if the shim is low i.e. gap is less then it can break the
components.

Basic arrangement of input, output and main shaft-

Input

Main shaft

Inner

Output

Outer

Couplings

Terms/components used in this process-

Top Gear

Output shaft

Main Shaft

Retainer

Shim Gauge

Three types of shims used in the process-

11

Standard Process of Shimming1. B of output shaft is coupled with B of main shaft.

2. Retainer is inserted in the highlighted area and hammered.

3. Shim reading machine attached.

Shim gauge

4. Shim gauge is inserted from top.

Retainer

5. Reading is taken by the machine.

6. The machine is unclamped and the gauge is removed.
7. The standard range is 18 Thou to 48 Thou, now if the reading comes out to
be 44 that means theres a gap of 44 thou and we have three types of shims
i.e. 11, 5 and 3 to fill 44 thou, we can use 4 shims of 11 size, similarly if 38 is
the reading we can use three shims of 11 size and one of 5 size.
8. Retainer is removed and shims are inserted.
9. Retainer is attached again and bolts are tightened.

QRQC Analysis of Shim Problems:

Step-1- Acknowledge the concern reported
Customer Voice/Complaint- Shim high.
Sharp definition of the problem(5W-1H)Shim high, on 15th February 2016 at transmission assembly
line, QRQC analysis of the problem will throw some light on
the actual causes of the problem.
Step-2- Immediate correction to the problem
immediate response- C.T. kept aside for check

Step-3- Root cause analysis

Root cause- wrong shims used

Step-4- Corrective Action

Corrective actionstandard procedure of shimming should be followed carefully, less
attentiveness might result in shim high or low.

7.3 Noises
Noises from the transmission box is not a good indication,
The sounds that are produced vary widely between different makes and models,
but the best way to describe them is that youll probably hear a humming,
buzzing or whining noise.
Manual transmissions will emit sounds that can be described as being slightly
more mechanical, louder and abrupt sounding. A clunking sound when you shift
gears almost always lies within a transmission, while constant velocity joins or
the differential may be the source.

Types of noisesHi-Point- rattle like sound, due to improper teeth, cut on teeth.
Humming- friction sound, it is caused due to casting and no proper gap
between gears.

QRQC Analysis of Transmission Noise:

Step-1- Acknowledge the concern reported
Customer Voice/Complaint- Noise from input
Sharp definition of the problem (5W-1H)hi-point noise from input, when running in neutral condition, Dent on 2 nd gear
teeth(visual).

Step-2- Immediate correction to the problem

Immediate response2nd gear changed,

Lead/Profile graph check (2nd gear): To check that 2nd gear is normal or not we
perform this profile/lead test, profile is checked from root to tip, while the lead is
checked from bottom to top.

Lead and profile were found to be normal.

DOP check (second gear)-DOP is diameter over pin :

DOP was checked at three points and was found to bePoint 1: 6.706
Point 2: 6.707
Point 3: 6.707
DOP of second gear was also found to be normal, hence problem in input shaft.

Step-3- Root cause analysis

Root causeInput shaft teeth broken due to improper handling of parts, no error in
machining process, oil groove might chip off during assembly(input shaft)

Step-4- Corrective Action

Corrective actionImproper handling of parts, the input shaft was inspected properly before
coming to the assembly, it must have been dropped by a worker which lead to
its breakage, parts should be handled carefully and should not be used again if
found faulty.

QRQC Analysis of reverse gear not working :

Step-1- Acknowledge the concern reported
Customer Voice/Complaint- reverse gear not working
Sharp definition of the problem (5W-1H)- proper reverse gear not found(EPI model),
reverse gear not able to match idler gear.

Ideal position of idler gear and reverse gear.

Step-2- Immediate correction to the problem

Immediate response- reverse gear changed and inspected.

Step-3- Root cause analysis

Root causeReverse gear used in EPI model should have 30 teeth while the reverse gear used in this case
was of 41 teeth.
Human Error
Reverse gear not checked properly on testing stage or bypass.

Step-4- Corrective Action

Corrective actionStrict rules should be made,
Proper handling of parts should be done,
training to be given to all the workers about job in hand,
Warning letter to be given to worker for being slack/careless next time .
Such kind of errors can be avoided by following proper color coding techniques and poka yoke
processes.
Although many such practices are already followed in the company but are not effective to their
full potential.

Color coding:

Color coding done for different types of reverse gears

QRQC analysis of Dowel not able to seat on rear plate

Step-1- Acknowledge the concern reported
Customer Voice/Complaint- Dowel not able to seat on rear plate.

Sharp definition of the problem (5W-1H)- Dowel not able to sit properly at its desired place
at rear plate of C.T., on hammering it is not going in beyond a particular length.
Step-2- Immediate correction to the problem
Immediate responseDouble hammering done, still not able to fit in, plate changed.
Dowels taken to the Inspection department for measuring its length and diameter:
Length was found to be 0.8055 inch,
height was.5001 inch
These fall into the standard acceptable size of the dowel.
Depth: 0.678 inch
Diameter: 0.482 inch
Rear plate holes measured.

Depth: 0.678 inch

Diameter: 0.482 inch

Depth: 0.6805 inch

Diameter: 0.481 inch

Both the holes were of standard acceptable sizes.

Step-3- Root cause analysis
Root cause- As both the dowels and the holes on rear plate were of standard acceptable sizes,
this means that there is no problem in both of them.
While following the case it was found that the height of the locating pin on the bed was
increased two weeks ago as during the regular process of dowel pressing, while hitting the
plate was coming out, guiding diameter of the locating pin was increased,

So as the height of the locating pin was increased less gap remains when the rear
plate is placed on the bed this makes it difficult for the operator to hammer the dowels
correctly into its place.
Step-4- Corrective Action
Corrective actionEngineers from the machining department were called to measure the specifications
of the bed, length of locating pin.
A turning was performed over the locating pin of the bed to reduce its height.

QRQC analysis of Part inside C.T.:

Step-1- Acknowledge the concern reported
Customer Voice/Complaint- Part inside C.T.
Sharp definition of the problem (5W-1H)- while performing the oil leakage
test, bolt accidentally dropped inside C.T.
Step-2- Immediate correction to the problem
Immediate responseC.T. kept aside for bolt removal.
Step-3- Root cause analysis
Root cause- Improper handling of parts and subparts, too many parts in hand.
Falling of bolt during oil leakage test:

oil leakage test being performed

tightening of bolts using pneumatic gun

While performing the oil leakage test the coverlid/plate on the C.T. is removed so bolts are unfastened
using the pneumatic gun,
The bolt sticks to the pneumatic gun and unfastened one by one
The lid is removed oil leakage test is performed.
After the test is performed successfully, the cover lid is placed on its position and bolts are fastened
using the pneumatic gun, this step can again lead to falling of bolt inside the C.T.
Step-4- Corrective Action
Corrective action-

bolts being placed in their grooves after placing the cover lid.

Careful handling of parts and sub parts in future is the most important and most
necessary corrective action step that can be taken in this case.
Suggestion of Placement of a magnetized tray in the centre and at bottom portion
inside the C.T. so if anything falls inside will reach bottom and due to the
magnetized tray it will stick to it and as the tray is placed strategically inside the
C.T. it has a feature of press and release function, when pressed from below it opens
up throwing the unwanted part in C.T. outside.
Suggestion of a fixture being placed over the little C.T. opening while the
unfastening and fastening of bolts during the oil leakage test, so if during the test
anything falls inside the C.T. it will fall into the fixture and the fixture can easily be
removed after the oil leakage test is performed hence also removing the fallen part
along with it.

QRQC analysis of Seal getting break while pressing process in the front
retainer:

burr found inside the retainer

Step-1- Acknowledge the concern reported
Customer Voice/Complaint- Seal getting break while pressing process in the front
retainer.
Sharp definition of the problem (5W-1H)- seal getting break while pressing process
in front retainer, 62/10 ball bearing scratching the inner portion of front retainer of double
clutch model (face slip).
Step-2- Immediate correction to the problem
Immediate response- Internal diameter of retainer checked.

Step-3- Root cause analysis

Root causeInternal diameter of the retainer was checked and found to be between 3.124
inch and 3.126 inch, the internal diameter was normal, on further inspection it
was found that there was a small burr in every piece of the fresh lot of retainers
Step-4- Corrective Action
Corrective actionSand paper polish to remove the burr in the remaining retainers:
The interior portion of the retainer was polished using sand paper, this helped
in removing the small burr inside the retainer.
Vendors alerted about the presence of a small burr in all the retainers of the
fresh lot.

QRQC analysis of main shaft not able to fit

Step-1- Acknowledge the concern reported
Customer Voice/Complaint- Main shaft not able to fit.
Sharp definition of the problem (5W-1H)- main shaft lock not able to fit in
properly with the third gear.
Step-2- Immediate correction to the problem
Immediate response- C.T. kept aside for rework
Step-3- Root cause analysis
Root causeWrong Gears used: on rework it was found that two reverse gears were present and
a third gear was absent.

The operator fixing 3rd gear had accidentally placed a reverse gear instead of the 3rd
gear.
Step-4- Corrective Action
Corrective actionEnsuring proper organization in keeping right gear at right spot.
Training provided to all the workers, even the ones meant for keeping right part at
right place.
Operators made aware about the types of color coding used on different parts

THANK YOU