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Presentation on a six sigma Project

Presented To: Presented By:

Mr. Rakesh Kumar Mr. Suraj Kumar Gupta
Asst. Professor Mech. Engg. B.Tech(ME)
Jagannath University 8th sem

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SIX SIGMA PROJECT

PREVENTION OF SCORING ON
BEARING SHELLS
(QUALITY ASSURANCE)

Under Guidance
Mr. Rishikesh Dabhade
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 Why 6 Sigma???
 Six Sigma seeks to improve the quality of
process outputs by identifying and
removing the causes of defects (errors)
and minimizing variability in
manufacturing and business processes.
 A six sigma process is one in which
99.99966% of the products manufactured
are statistically expected to be free of
defects (3.4 defective parts/million).
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DMAIC TIME PLAN

YEAR2014
PHASE
JAN FEB MAR APR MAY JUN

De fine

Me as ure

Analys e

Im prove

Control

PLANNED ACTUAL
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DEPARTMENT INVOLVEMENT

DEPARTMENT D M A I C
RECTIFICATION AREA
P P P P
WASHING AREA
P P P P
ASSEMBLY LINE
P P P P
CRANKSHAFT LINE
P P P P
CYL. BLOCK LINE
P P P P
CAMSHAFT LINE
P P P P

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PROJECT CHARTER
PROJECT TITLE:
Prevention of Scoring on Bearing Shells

PROJECT DESCRIPTION:
In the last month January 2014 , during Bearing Inspection it has been found that bearing shells of many
engines got scored. Total numbers of engines (having scored bearing shells) were 23 in January, while in
previous year, each month had maximum 4 Nos. engines having scored bearing shells.

SCOPE:
Area: Cylinder Block line, Crankshaft line, Camshaft line, Assembly line, Washing & Rectification area
Applicable Plants: Tata Motors, Jamshedpur
Main Parts: Crankshaft, Cylinder block & bearing shells

GOAL:
Elimination of root causes for negligible or no scoring on Bearing Shells during BI

TIMELINE:
24TH January 2014 to 30th June 2014

TEAM MEMBERS:
Project Sponsor : Mr. S K Sinha (AGM, Engine Machining)
Project Mentor : Mr. Rishikesh Dabhade (Sr. Manager, Crankshaft line)
Project Promoter : Mr. Ohm Prakash (Manager, Crankshaft line)
Project Leader & Member : Mr. Suraj Kumar Gupta
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BUSINESS CASE

Project Title: Scoring in Bearing Shell of Main Bearing & Crank Pin Bearing

Project leader: Mr. Suraj Kumar Gupta Project Function : Engines

Defect Definition? Why this Project?

Scoring in bearing shells of MBs & CPS This project is undertaken to determine
and in some engines also on journals of and eliminate the causes of bearing shells
MBs & CPs, due to which many engines scoring and reduce the chances of bearing
were brought for BI (Bearing Inspection). failure.

Project CTQ’s: Business Results:

•Crankshaft machining & cleaning •Reduction in changing of bearing shells
•Cylinder block cleaning •Reduction in the number of engines for BI
•Assembly cleanliness •Reduction in rework of crankshaft
•Increase Customer satisfaction

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What is Voice of Customer ?

In Bearing Inspection it has
been found that bearing shells of many engines
got scored, if they did not get scored then at least
every engines which are brought for BI had
circumferential lines on inner surface of bearing
shells and/or on journal.

What is Voice of Customer indicating ?

VOC indicates that the
cleanliness of oil hole of crankshaft & cylinder
block are not proper and oil hole chamfering is not
good.
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What is Bearing Inspection ( BI ) ?

 Bearing Inspection is an important activity after
engine testing. Every 50th engine after testing is
brought in rectification area for BI where all the
MBs caps & con rod caps are untorqued and then
remove them from engines.
 After that, all MBs & CPs and their caps including
their bearing shells are checked and verified with
QA Inspector for dent mark or any type of
damage/scratch mark on the bearing shells.
 Since BI found NOK in many engines so every 25th
engine after testing is going to collect for BI.

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CTQ FLOWDOWN

Bearing shell
scoring

Crankshaft
Cylinder block Assembly
machining &
cleaning cleanliness
cleaning

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SIPOC

SUPPLIER INPUT PROCESS OUTPUT CUSTOMER

ASSEMBLY COMPLETE REASSEMBLED DISPATCHING

LINE ENGINE ENGINE AREA
Engine Testing

Load the engine on working fixture, untorque drain plug & remove the engine oil in a jar

Rotate the engine 180° and untorque oil sump mtg bolt and remove oil sump

Untorque oil pump mtg bolt & remove the oil pump

Untorque con rod 1&6, 2&6, 3&4 and all MB caps

Check & verify all bearing shells for dent mark or any type of damage/scratch
If NOK in BI If OK in BI

Change the bearing shells

and/or crankshaft Reassemble the engine

BEARING INSPECTION OPERATION SEQUENCE

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MONTHWISE BEARING INSPECTION DETAILS

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MB wise scoring (Oct’13 to Jan ‘14)

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Types of scoring
• Deep dent mark
• Light dent mark
• Scratch
• Circumferential scoring
• Deep & Light lines

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Deep dent mark

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Light dent mark

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Scratch

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Circumferential scoring

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Deep & light lines

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BEARING INSPECTION IN FEB’14

ENGINE CRANK MB MB MB MB MB MB MB CR CR CR CR CR CR
NO. SHAFT NO. 1 2 3 4 5 6 7 1 2 3 4 5 6

BVY1575 BFc14A0398 LS P P DS P P P P P P P P P
BVY1600 BFc14A0488 P P P P P P P P P P P P P
BVY1625 T14A0564 P P P P P LS P P P P P P P
BVY1650 BFc14A0486 P P P P P P P P P P P P P
BVY1675 T14A0528 P P P P P P P P P L P P P
BVY1700 T14A0604 P P DS P P P P P P P P P P
BVY1725 BFc140424 P P LS P P P P P P LS P P P
BVY1745 BFc14A0695 P LS P P P P P P P P P P P
BVY1775 T14A0567 P P P P P L P P P P P P P
BVY1800 T14A0248 L L P P P P CS P P P L L P

LS :Light Scored , DS :Deep Scored , CS :Circumferential scored , L :Lines

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BEARING INSPECTION IN FEB’14

ENGINE CRANK MB MB MB MB MB MB MB CR CR CR CR CR CR
NO. SHAFT NO. 1 2 3 4 5 6 7 1 2 3 4 5 6

BVY1825 BFc14A0543 P P P L L P P P P P P P P
BVY1850 BFc14A0550 P P P P P LS P P P P P P P
BVY1815 T14A0554 L L L L L L P P P L P P P
BVY1897 T14A0208 LS P P P P P P P P P P P P
BVY1818 T14A0366 P P P P P P P P P P P P P
BVY2350 T14B0276 P P LS P P P P P P P P P P
BVY2400 T14B0156 P P P P P P P P P P P P P
BVY2450 BFc14A0697 P P L P P L P P P P L P P
BVY2700 BFc14B0052 P P P P P P P P P P P P P
BVY2750 BFc14B0196 P P P P P P P P P P P P P

LS :Light scored , L : Lines

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Possible factors of bearing scoring

 Dirt
 Chips
 Insufficient oil supply
 Overheating
 Improper machining of engine components
 Misalignment of engine components
 Assembly errors
 Bearing clearances
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Cause & Effect Diagram

Camshaft Crankshaft
Poor Journal surface finish
Oil pump Burrs on gear teeth
Improper Oil hole chamfering
Run out of MBs
Low oil greater than max value
Dust or chips in oil hole
pressure
Dust or chips in oil hole
Scoring on
bearing shell
Dirt on bearing back
Imperfect Material
cooling defects Use of std. size Burrs on cam bush
bearing shell in
Oil cooler undersized or
Variation in oversized journal Dust or chips in oil hole
critical
dimension Dirt in lubrication Errors in lock groove
system

Bearing shell Assembly Cylinder block

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Crankshaft line
Station Process Cause
No:
170 OHC & Inspection Improper chips cleaning of oil hole gallery
(before induction after drilling due absence of air gun with 6ϕ
hardening) pipe.

410 OHC & Deburring •Larger & square shape of emery paper(grit
120) not polishing high point at oil hole
opening. There is no predefined centre point
of rubber & emery paper.
•Improper chips cleaning of oil hole gallery
of crankshaft due absence of air gun with 6ϕ
pipe.
•Due to Manual operation of chamfering
operator sometimes forget to polish any oil
hole opening with grit 120.

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Crankshaft line
Station Process Cause
No:
430 Lapping Cutting oil not filtered properly because
magnetic separator not working properly.

440 Washing Insufficient pressure due to jammed washing

nozzles.

460 Final inspection •There is no magnetic equipment(stick) to

remove chips from oil gallery.
•There is no mean of checking of bearing
scoring

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Cylinder block line

Station Process Cause
No:
470 Cam bush pressing During cam bush pressing , burrs generate on
the outer surface of cam bush. In many
cyl.block these burrs are present even after
washing.
490 Lock groove on MB Improper fixing of cyl.block on fixture leads
milling to height loss or height gain and further lead
to error in lock groove.

550 Final inspection of •Improper cleaning of oil gallery , when

cyl.block operator blow the air from air gun then some
chips are move to other position but remains
in the cyl.block.
There is no magnetic equipment at inspection
point of cyl.block to remove the chips from
oil gallery.
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Camshaft line
Station Process Cause
No:
40 Oil hole drilling Four different holes are drilled (oil hole ϕ 6,
eccentric ϕ 3, MB4 & MB1 ϕ 4) but operator
uses single device to apply compressed air
for removing of chips from all the holes.
130 Gear buffing Buffing wire pattern of buffing wheel got
irregular due to which burrs of gear teeth can
not be removed properly.

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Assembly line
Station Process Cause
No:
SBL 03 Placing of upper bearing The presence of a foreign particle trapped
shell on bore of cyl.block between the bearing back and its
housing will lead to a raised area, with the
ensuing risk of contact between this
protruding high-spot and the journal.
SBL 05 MB cap fitment with lower The presence of a foreign particle trapped
bearing shell between the bearing back and its
housing will lead to a raised area, with the
ensuing risk of contact between this
protruding high-spot and the journal.
SBL & The presence of dirt particles entrained in the
LBL lubrication system during assembly(working
hours) and non-working hours.

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BEARING
MB E3
( Menon Bearing Euro 3 )
Part No: 252703123119
Application: 497/697 main bearing lower

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THANKS

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