Reducing Rejection Rate in Pump Casing Assembly by Using Tpm

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PRESENTED BY

A.Balasubramani(08030610017)

M.Devarajan(08030610026)

G.Kanagaraj(08030610049)

SUPERVISOR

Mr. R. SATHIYA MOORTHY, M.E, (Ph.D)

Assistant Professor

Dept. of Mechanical Engineering,

Anna University of Technology,

Coimbatore – 641047.

2 Department of Mechanical Engineering

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Objective

Reducing rejection rate in pump casing assembly

line process by using TPM.

Methodology Available To Solve Problems TPM

CFT approach

10 step approach

Quality circle

6 sigma

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TPM Methods to solve problem PDCA Cycle

Cause and Effect Analysis

Gap Analysis

Why-Why Analysis

Kaizen

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Our Method of Solving

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Product Process Flow

Welding-1 • Projection Welding

Welding-2 • Spot Welding

Welding-3 • Projection Welding

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Problem Details

Product rejection rate in pump casing assembly line

is 539ppm.

Stage 1- Plan

Pump Casing Assembly Line Process is Selected For Our Project, Due to More Rejection Found (539 ppm)

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Sl.No Process Rejection PPM

1 Projection Welding-1 92

2 Spot Welding 364

3 Projection Welding-2 83

Total 3-Process 539

Process wise Rejection Status

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Process Defect Rejection Qty Per 5000

Nos Rejection PPM

Projection Welding-1

Product Missed Weld 0.34 68

Dislocating 0.05 10

Improper Parameter 0.07 14

Spot Welding Misaligned Welding 1.75 350

Improper Parameter 0.07 14

Projection Welding-2

Product Missed Weld 0.305 61

Dislocating 0.05 10

Improper Parameter 0.06 12

Defect wise Rejection Details

In Spot Welding Process Misaligned Welding Rejection is more found.

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Misaligned Welding Rejection product

Existing Method of Operating

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Goal is to eliminate the spot welding process rejection in pump assembly casing assembly to zero ppm within a ppm of one month

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Goal:-

Stage-2:- Do Analyzing the Facts :

By using Cause and effect analysis Possible causes of misaligned welding found.

By using the why-why analysis finding the solutions for the causes.

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Cause and Effect Analysis For Misaligned Welding

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Causes of Misaligned Welding

Product locating method.

Improper handling method.

Machine Operating Speed.

Training to the operators.

Human Fatigue.

Machine Parameters.

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Why-Why Analysis

Q1:Why Product Locating Method is Wrong?

Ans : Product Locating depends on operator

Q: Why Product Locating depends operator?

Ans : There is no proper locating fixture

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Solutions For Misaligned Welding

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Sl.No Machine Causes of Misaligned Welding Countermeasure

1 Spot Welding Product Dislocating. Providing new fixture to locating the product with proper

welding path radius

2 Spot Welding Improper handling. Providing new fixture to holding & welding the product.

3 Projection Weld Fixture material strength. Providing new fixture with proper material strength.

4 Spot Welding Machine Speed. Providing flow control valve for the incoming Compressed

air.

5 Spot Welding Operator Training. Providing enough training to the operator.

6 Spot Welding Human Fatigue. Providing new fixture to holding the product.

By Providing the proper locating Fixture the 350ppm of rejecting can be eliminated in spot welding process.

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Stage 3: Check

Proposed Fixture

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Process Defect Rejection Qty Per 5000

Nos Rejection PPM

Projection Welding-1

Product Missed Weld 0.2 40

Dislocating 0.05 10

Improper Parameter 0.07 14

Spot Welding Misaligned Welding 0 0

Improper Parameter 0.03 6

Projection Welding-2

Product Missed Weld 0.2 40

Dislocating 0.03 6

Improper Parameter 0.06 12

Defect wise Rejection Details After Implementation of New Fixture

Stage 4 :- Act

Monitoring the solution

Kaizen Idea Sheet

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Result By implementing the new welding fixture for spot

welding process rejection rate in pump assembly casing assembly is reduced to zero ppm

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Future Enhancement By using the electric, hydraulic, pneumatic, and

hydro-pneumatic control systems and also with the help of robots handling this operation .Also this process can be integrated with machine, so man power is not required for handling the component. The component can be moved to weld the required path by using PLC programming.

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References Kaizen complied by Masaaki Imai “TPM introduction,

implementation, kaizen, PDCA-Cycle”

Design of jigs, fixtures, and press tool Complied By Erik Karl Henriksen “Fixture design principles, locating principles”

Statistical quality control by Steven M.Zimmerman,Marjorie L “7 Quality tools, check sheets, pareto analysis”

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Thank You