PRESENTATION ON YP-8 INSIDE HANDLE ASSEMBLY

FIXTURE

Presented By: Vipul Bhardwaj

Quality Issue Raised By The Customer

Wrong Knob Fitment In The Handles.

Daily Supply Of Approximately 10000 HandlesReported Issues: 8-10 Pieces Per Day

Traditional Assembly Method

Traditionally the assembly was used to be done by free hands.

The final assembled pieces are then checked for the quality issues by the quality inspectors.

The final quality checked pieces were then sent to the customer (MSIL in this case).

Solutions Of This Issue Many solutions were proposed for the

same by different persons involved in it. Among them, 2 solutions were tried to

carry out.1. Changing the moulding method and

separating the assembly lines plants for the left and right handles assembly.

2. Designing an assembly fixture for assembly process.

Solution Number - 1 In this solution, the moulding machines

were run to produce only 1 side knobs in a shift.

Produced knobs were used for the assembly in that specific plant only for that particular side handle.

Drawbacks:1. Highly inefficient process as there was

high underutilisation of the machine resource.

2. Difficulty in integrating the assembly lines in different plants as per the customer order.

Solution Number -2 This solution was the best one and was

implemented as well. The assembly fixture for the handles

were designed and fabricated. The assembly of the handles were done

in the fixtures instead of free hand. Fool-proofing (poka-yoke) of the process

as to eliminate the customer’s raised issue of wrong knob.

Assembly Fixture Design For The Handle Assembly

Assembly Process On The Fixture

So this is what was carried out for the assembly of handles to eliminate the quality issue and to give a happy ending to the customer.

The process started with the designing of the assembly fixture, its fabrication and then the end use of it for the assembly production.

The thing which was to be kept in mind while designing of it was to match the daily production of the handles as per the customer demand with minimal amount of the additional input resources.

Earlier the production rate was around 110 handles per hour.

The production rate after the implementation of the assembly fixture was around 100 handles per hour.

There was not much decrease in the production rate but the gain of customer delight was achieved which eventually increased the quality level of the company in the sight of the customer.