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Kaizen Group PresentationKaizen Group Presentation
Super Turbo GroupSuper Turbo GroupWelcomes You allWelcomes You all
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Organization InformationOrganization Information
Products
Tractors & Engines
Products
Tractors & Engines
Market Leader
in
Tractor Industry since last
23 years
Market Leader
in
Tractor Industry since last
23 years
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Qu ality Jo u rneyQu ality Jo u rney
ISO9001 -A u g us t 1996
Q S 9000 - May 2000
ISO14001 - 2003
Deming Award - Nov.2003
Japan Qu ality Medal ( planned ) - Nov. 2006
Mahindra i s Fir s t Tractor company in the World
to achieve Deming Award
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K aizen Gro u p InformationK aizen Gro u p Information
N ame : - ³Super turbo´
Meeting Frequency:- Weekly every Monday 2.00 PM (1 hr)
N ame of Members :-
Formation : - J un 04
Product unit : - Testing & Evaluation (Product Development Group)
Facilitators : - Mr. Deepak T hakur & Mr. A.D. Kulkarni
Mr. Prakash K. LattooMr. Sanjay K. Patil
Mr. Dinesh Gadekar
Mr. Parag M.Panse - Leader
Mr. Bhushan K. Patil - Dy. leader
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R esolution
Of Engine Failure
Due toLub.Oil Pressure Drop
R esolution
Of Engine Failure
Due toLub.Oil Pressure Drop
C a s e St u dyC a s e St u dy
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S teps Adopted S teps Adopted
Defining the problem
Data Collection for deciding core of the problem
Identification Of Causes
Selection of probable causes
Testing of Probable causes
Developing Solutions
Validating Solutions
Trial implementation
Field Trial & Review
Regular Implementation
Management Review
1
2
3
4
5
6
7
8
9
10
11
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Defining the problem
In trial batch of newly developed 30 Hp Model, Severe performance
drop observed on 11% tractors during initial 350 Hrs. of usage.
S tepS tep - -11
- Horse power of engine dropped from 30 hp to 22 hp.
- Lubrication oil pressure dropped from 3.12 bar to 0.8 bar.
Background of the Problem
L a u nching of 30 Hp model wa s Stopped
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On the basis of detailed analysis , the problem is defined as ;
Definition of the Problem
³Engine Fail u re d u e to L u b. oil
pre ssu re drop´
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S teps Adopted S teps Adopted
Defining the problem
Data Collection for deciding core of the problem
Identification Of Causes
Selection of probable causes
Testing of Probable causes
Developing Solutions
Validating Solutions
Trial implementation
Field Trial & Review
Regular Implementation
Management Review
1
2
3
4
5
6
7
8
9
10
11
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After detail failure analysis of field returned engine, following
major observations were recorded .
Problem reported after initial 350 Hrs. of usage in field
application (Under Hyd Pump Loading.)
Problem reported during field testing of trial batch. 2 tractorsout of 19 were observed defective.
Data C ollection for deciding coreof the problemS tepS tep - -22
1. Crank case first cam bore wear excessive. (144 micron against 15)
2. Cam shaft first journal wear excessive.(90 micron against 15)
3. Valve hitting marks on piston top surface.
4. Both Push rods of first cylinder found bend
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S teps Adopted S teps Adopted
Defining the problem
Data Collection for deciding core of the problem
Identification Of Causes
Selection of probable causes
Testing of Probable causes
Developing Solutions
Validating Solutions
Trial implementation
Field Trial & Review
Regular Implementation
Management Review
1
2
3
4
5
6
7
8
9
10
11
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Identification Of C a us e sIdentification Of C a us e sS tepS tep - -33
C ambore oilhole
mi s matched
Ass y Error
C am s haft boltnot torq u ed
No float incam s haftsu b a ss y
Thr us t wa s hera ss y in rever s e
direction
L e ss torq u e val u e of cam s haft bolt
Exce ss ive parent cambore ovality
C am bore u nder s ize
C am s haft dia over s ize
C rankca s e materialnot O K
Exce ss ive cam s haftJr. dia r u n o u t
Exce ss ive cam s haftgear thr us t face r u n o u t
C am s haft thr us theight le ss
Oil s tarvation d u e tole ss oil su pply
30 hp engine de s ign errorcompare with proven engine
De s ign clearancebetween cam
bore & s haft i s le ss
C am bore thr us tface area i s le ss
Engine oil pre ssu rebelow min.
req u irement
C am s haft de s ignedfloat i s le ss
Direct materialcontact
MATERIA L METHOD
MA C HINEMAN
Engine l u boil
pre ssu redrop
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S teps Adopted S teps Adopted
Defining the problem
Data Collection for deciding core of the problem
Identification Of Causes
Selection of probable causes
Testing of Probable causes
Developing Solutions
Validating Solutions
Trial implementation
Field trial & Review
Regular Implementation
Management Review
1
2
3
4
5
6
7
8
9
10
11
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Engine l u boil
pre ssu redrop
S tepS tep - -44 Selection of probable ca us e sSelection of probable ca us e s
C ambore oilhole
mi s matched
Ass y Error
C am s haft boltnot torq u ed
Thr us t wa s hera ss y in rever s e
direction
L e ss torq u e val u e of cam s haft bolt
Exce ss ive parent cambore ovality
C am bore u nder s ize
C am s haft dia over s ize
C rankca s e materialnot O K
Exce ss ive cam s haftJr. dia r u n o u t
Exce ss ive cam s haftgear thr us t face r u n o u t
C am s haft thr us theight le ss
Oil s tarvation d u e tole ss oil su pply
30 hp engine de s ign errorcompare with proven engine
C am bore thr us tface area i s le ss
Engine oil pre ssu rebelow min. req u irement
C am s haft de s ignedfloat i s le ss
Direct materialcontact
MAN MA C HINE
METHODMATERIA L
No float in cams haft su b a ss y
De s ign clearancebetween cam bore
& s haft i s le ss
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Engine l u boil
pre ssu redrop
MAN MA C HINE
METHODMATERIA L
S tepS tep - -44
Ass y Error
No float in cams haft su b a ss y
Exce ss ive cam s haftJr. dia r u n o u t
Exce ss ive cam s haftgear thr us t face r u n o u t
Oil s tarvation d u e tole ss oil su pply
De s ign clearancebetween cam bore
& s haft i s le ss
Engine oil pre ssu rebelow min. req u irement
Direct materialcontact
Selection of probable ca us e sSelection of probable ca us e s
1
2
3
4
5
6
7
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S teps Adopted S teps Adopted
Defining the problem
Data Collection for deciding core of the problem
Identification Of Causes
Selection of probable causes
Testing of Probable causes
Developing Solutions
Validating Solutions
Trial implementation
Field Trial & Review
Regular Implementation
Management Review
1
2
3
4
5
6
7
8
9
10
11
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S tepS tep - -5 5
Excessive camgear thrustface run out
Checkedfailed engineGearparameter
Withinspecified
limit
Cause invalid
Float valuesverified from
Assy data
No float inCam shaft
sub assy
Testing of Probable causesTesting of Probable causes
1
2
3
Excessive camshaft journaldiameter run
out.
CheckedValues inAssy
Ob s ervation C oncl us ionC a us e Te s t MethodNo.
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S tepS tep - -5 5
InsufficientDesignedclearances.
Value comparedwith provenengine
Out of
specified
limit
Cause valid
Test comparedwith proven
engine
Oil starvationdue to less
oil supply
Testing of Probable causesTesting of Probable causes
4
5
6
Mechanicalcontact of camshaft & cambore
Tested underHyd loading
Ob s ervation C oncl us ionC a us e Te s t MethodNo.
Seizuremarks areobserved on
cam shaft journal
Cause valid
With inspecifiedlimit
Cause invalid
5
4
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S tepS tep - -5 5 Testing of Probable causesTesting of Probable causes
With in
specifiedlimit
Cause invalid
Verified from
the testresults
Engine Initial
oil pressurebelowminimumrequirement
7
Ob s ervation C oncl us ionC a us e Te s t MethodNo.
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S teps Adopted S teps Adopted
Defining the problem
Data Collection for deciding core of the problem
Identification Of Causes
Selection of probable causes
Testing of Probable causes
Developing Solutions
Validating Solutions
Trial implementation
Field Trial & Review
Regular Implementation
Management Review
1
2
3
4
5
6
7
8
9
10
11
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Developing SolutionDeveloping Solution
Brain storming conducted for probable solutions
1) Increase oil supply hole size in cam
bore from 8mm to 10mm.
2) Remove circular groove from cam journal
3) Reduce oil hole size of gear lubricationfrom 3mm to 1mm
S tepS tep - -66
4) Relocation of Oil supply pipe closer tofront cam bore.
Oil starvationdue to less oilsupply
Mechanical
contact of cam
shaft & cam
bore
Probable Sol u tion sC a us eNo.
5
4
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S teps Adopted S teps Adopted
Defining the problem
Data Collection for deciding core of the problem
Identification Of Causes
Selection of probable causes
Testing of Probable causes
Developing Solutions
Validating Solutions
Trial implementation
Field Trial & Review
Regular Implementation
Management Review
1
2
3
4
5
6
7
8
9
10
11
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Validating SolutionsValidating Solutions
Propo s ed Sol u tion s
1Increased oil hole size
in cam bore
S tepS tep - -7 7
Modification s Te s t Re su lt sSol u tion
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Increa s ed oil hole s ize in cam bore
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Validating SolutionsValidating Solutions
Propo s ed Sol u tion s
1Increased oil hole size
in cam bore
S tepS tep - -7 7
Modification s Te s t Re su lt sSol u tion
Elimination of groovefrom cam journal
2
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Validating SolutionsValidating Solutions
Propo s ed Sol u tion s
1
Increased oil hole size
in cam bore
Oil hole size reduced infront cover
3
S tepS tep - -7 7
Modification s Te s t Re su lt sSol u tion
Elimination of groovefrom cam journal
2
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Oil hole s ize red u ced in front cover
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Validating SolutionsValidating Solutions
Propo s ed Sol u tion s
1
Increased oil hole size
in cam bore EngineTestingwith Hyd
loading in
lab
Oil Pressure
drop
continued
Oil hole sizereduced in frontcover
3
S tepS tep - -7 7
Modification s Te s t Re su lt sSol u tion
Elimination of groovefrom cam journal
2
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Exi s tingArrangement
C am Bore(Oil s tarvation)
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4
Relocation of Oil supply
pipe closer to front
cam bore.
Final Sol u tion
Validating Final SolutionValidating Final Solution
Modification s Te s t Re su lt sSol u tion
S tepS tep - -7 7
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Oil starvation due to less oil supply-
Tappet making restrictionto oil flow
Developing Final SolutionDeveloping Final Solution
Details study of oil passages showed Oil passage is getting
partially blocked by tappet coming in front of oil inlet.
70%
Hole Blockage
S tepS tep - -7 7
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Validating SolutionStepStep --88
70% Hole Block 100% Hole Open
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Exi s tingArrangement
C am Bore(Oil s tarvation)
Final Sol u tion
C am Bore(No oil
s tarvation)
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4
Relocation of Oil supply
pipe closer to front
cam bore.
No Oil Pressure
drop.
Final Sol u tion
Validating Final SolutionValidating Final Solution
Modification s Te s t Re su lt sSol u tion
C oncl us ion - Oil pre ssu re drop eliminated. Sol u tion effective
S tepS tep - -7 7
EngineTestingwith Hyd
loading inlab
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S teps Adopted S teps Adopted
Defining the problem
Data Collection for deciding core of the problem
Identification Of Causes
Selection of probable causes
Testing of Probable causes
Developing Solutions
Validating Solutions
Trial implementation
Field Trial & Review
Management Review
1
2
3
4
5
6
7
8
9
10
11 Regular Implementation
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2 nos. Of modified engines are built & tested under newly
designed hydraulic load cycle.
Trial implementation & checkingperformance in laboratoryTrial implementation & checkingperformance in laboratory
T he test results showed N o drop in oil pressure.
Wear of first cam journal & cam bore observed to be w ith in limit
(against 15 microns).
S tepS tep - -88
Successful Endurance test completed.
T he test results showed N o drop in po w er.
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S teps Adopted S teps Adopted
Defining the problem
Data Collection for deciding core of the problem
Identification Of Causes
Selection of probable causes
Testing of Probable causes
Developing Solutions
Validating Solutions
Trial implementation
Field Trial & Review
Regular Implementation
Management Review
1
2
3
4
5
6
7
8
9
10
11
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Propo s al pre s ented to the management & they
have approved & al s o highly appreciated
Propo s al pre s ented to the management & they
have approved & al s o highly appreciated
Management ReviewManagement ReviewS tepS tep - -99
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S teps Adopted S teps Adopted
Defining the problem
Data Collection for deciding core of the problem
Identification Of Causes
Selection of probable causes
Testing of Probable causes
Developing Solutions
Validating Solutions
Trial implementation
Field Trial & ReviewRegular Implementation
Management Review
1
2
3
4
5
6
7
8
9
1011
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T his improved design is implemented on 19 tractors of seeding
batch in the field.
Subject tractors are tested for different applications in field under
hydraulic load application (Cultivation etc.).
Feedback taken on detail monitoring done for oil pressure drop
& power loss.
Field Trial & ReviewField Trial & ReviewS tepS tep - -1010
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Randomly selected 2nos. Of tractors tested in field out of 19nos.
brought back to plant for conformance of solution.
Conducted lab performance test for power, oil consumption & oil
pressure in as received condition.
Lab performance found well within acceptable limits.
Tear down analysis of engine conducted.
Condition of front cam bore & journal found perfectly OK.
(Wear cam bore - 0.006mm & cam journal - 0.003mm against 0.015mm)
Field Trial & ReviewField Trial & ReviewS tepS tep - -1010
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S teps Adopted S teps Adopted
Defining the problem
Data Collection for deciding core of the problem
Identification Of Causes
Selection of probable causes
Testing of Probable causes
Developing Solutions
Validating Solutions
Trial implementation
Follow-up & ReviewRegular Implementation
Management Review
1
2
3
4
5
6
7
8
9
1011
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S u bject improvement i s implemented on prod u ction
batch of 904 no s . tractor s prod u ced till date.
S u bject improvement i s implemented on prod u ction
batch of 904 no s . tractor s prod u ced till date.
Regular ImplementationRegular Implementation
No c us tomer complaint till date
S tepS tep - -1111
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BenefitsBenefits
Produc t la unch e d s ucc essf u lly i n Oc t 2004
E n able d sale 904 no s s o fa r
Save d wa rr a n ty p ro bable co st o f 25,000 pe r t r a c t or Th is h as Imp ro ve d ma rk et s h a r e 30 H P r a ng e t r a c t or
0
20
40
60
80
100
120
140
N o
o f t r a c t o r s
M a y - 0
4
J u n - 0
4
J u l - 0 4
A u g - 0
4
S e p - 0
4
O c t - 0 4
N o v - 0 4
D e c - 0 4
J a n - 0
5
F e b - 0
5
M a r - 0 5
A p r - 0 5
M a y - 0
5
J u n - 0
5
J u l - 0 5
A u g - 0
5
Month
Launching
Planned Actual
% Defect
0 0
11
0
2
4
6
8
10
12
14
M a y
- 0 4
J u n -0
4
J u
l - 0 4
A u g
- 0 4
S e p
- 0 4
O c t -0 4
N o v
- 0 4
D e c -0 4
J a n -0
5
Month
% D
e f e c t
N o e ng i n e fail ur e obse r ve d till d ate
L a u nching Halted
Po ssible C u st ome r d issatisfa c ti on was av o i d e d N ew p roc ess d evel o pe d f or f u t ur e p roj e c t
S olution Developed &
Implemented
D efe c t f r ee p roduc t d evel o pe d bef or e la unch i ng
Warranty Cost (Cam w ear)
0 0
25000
0
5000
10000
15000
20000
25000
M a y
- 0 4
J
u n -0
4
J u
l - 0 4
A u g
- 0 4
S e p
- 0 4
O
c t -0 4
N o v
- 0 4
D e c -0 4
J
a n -0
5
Month
R s . P e
r T r a c t o r
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Competency building in solving problem using Kaizen.
Special Gains to MembersSpecial Gains to Members
S atisfaction for successfully solving critical product development problem.
Upgradation in the product development kno w ledge.
Team spirit has got boosted.
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Future PlanFuture Plan
Resolution of
Of Cam Bush R otation
In
60hp Engine
Resolution of
Of Cam Bush R otation
In
60hp Engine
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The woods are lovely dark & deep And I have promises to keep
And miles to go before I sleep And miles to go before I sleep
-Robert Frost
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V ote Of Thanks
Q C F I (Hyderabad)
&
Q C F I (Mumbai )
V ote Of Thanks
Q C F I (Hyderabad)
&
Q C F I (Mumbai )
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W ish You All
Happy
&
Prosperous New Year
W ish You All
Happy
&
Prosperous New Year
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H ydraulic Loading
Of
Engine
H ydraulic Loading
Of
Engine
Hydra u lic OperationHydra u lic Operation