To Decrease Internal Rejections During the Production Process.

1. Project Presentation
By:- Mohit Gupta
Roll No:- ME-10-B(TC)-40
Department:- Quality Analysis
@
GABRIEL INDIA LTD. PARWANOO

2. PROJECT:-Reduction of Internal Rejections
During the Process
Objective:-
 To decrease the internal rejections that is various defects like Piston
Rod Burn, Low Tension, Nugget Failure, Thread Damage,
Overflow, Paint on Piston Rod.
 To track the root cause of these internal rejections.
 To Suggest measures to minimize these problems.

3. How This Project Link up With My Course..?
 This project gave me an opportunity to use various
measuring components which is a key area of
engineering meteorology.
 This project also gave me the opportunity to know about
precision and accuracy which forms a key feature in
quality analysis and meteorology.

4. ROAD MAP
( 1st
JAN – 30th
JAN)
 Learned about the various assembly process
carried out in the plant.
 Type of defects and their probable causes.
 Analyzed different defects like thread damage,
overflow and nugget failure.
 Prepared Fishbone Diagrams regarding defects.

5. Fishbone Diagram for:-Defects in Paint Shop
Piston Rod Burn
Man
Method
Machine
Material
Measurement
Upper electrode
welded the metal stop
from side instead of topManual Error
Misalignment of upper
electrode and piston
rod
Indexing fixture bolt
loose
Checking frequency
not defined and no
checking mechanism
of bolt

6. Fishbone Diagram for:-Defects in Paint Shop
Dent Mark in Paint Shop
Man
Method
Machine
Material
Measurement
During Cleaning
Sometimes Application
Falls DownManual Error
Improper Hanging
Dent From the
Previous operation
Rough Loading and
Unloading

7. Fishbone Diagram for:-Defects in Paint Shop
Rough Surface-
Presence of dust
Particles
Man
Method
Machine
Material
Measurement
Environmental Dust
Manual Error
Paint-Primer Combination not ok
Conveyer Belt not
Clean
Improper Phosphate
Coating
Dusty Hand
Gloves Used

8. Fishbone Diagram for:-Defects in Paint Shop
Overflow
Man
Method
Machine
Material
Measurement
Improper Cleaning
Manual Error
Paint-Primer Combination not ok
Bubbling in the
Paint Gun
More Rotation of Conveyer
Phosphate
Coating not
ok
Paint Primer
Combination not ok

9. Fishbone Diagram for:-Defects in COMBI
Line
Thread Damage
Man
Method
Machine
Material
Measurement
DFT(Damping Force
testing) Alignment not
okManual Error
Material Composition not ok
Unskilled Man Power
Brass Holder not ok

10. ROAD MAP
(1st
FEB-28th
FEB)
 Post problem analysis was done.
 Learned about the causes of piston rod burn on
metal stop welding m/c.
 Implemented measures for eliminating piston
rod burn using 4 bolt indexing fixture.
 Implemented part direction sequence to reduce
rejection due to low tension.

11. Post Problem Analysis Report-1
Before:-Metal Stop Welding Machine Causing Piston Rod Burn
After :- Four bolt is used instead of two bolt in indexing fixture.
Before After

12. Post Problem Analysis Report-2
Before:-Internal Rejections due to Low Tension that is due to part reversed.
After :- Part direction reversed.
Before After
Part
direction Reverse
Part direction ok

13. OUTLOOK
BEFORE:
 In ALTO PISTON ROD the internal rejection of 16 no’s worth Rs
2576 were analyzed.
 In INDICA REAR the internal rejection of 3 no’s worth Rs 468
were analyzed.
AFTER:
 Now four bolt is used instead of two bolt in indexing fixture and
piston rod burn is removed .
 Part direction sequence is implemented hence rejection due to low
tension is decreased.

14. Result
 Root cause of internal rejections were tracked and measures were
suggested.
 Piston Rod burn on metal stop welding was eliminated using four
bolt indexing fixture.
 Rejection due to Low Tension decreased by implementing part
direction sequence.