Suneeth Review

REVIEW
PRESENTATION
Suneeth Kr. Behera

Engineer
R&D
© Subros Limited. All rights reserved
TRAININGS UNDERGONE
SR.NO. TRAININGS PLANNED ACTUAL
1 DNJP INTRO. OK COMPLETED

2 SAP AWARENESS OK COMPLETED
3 SERVICE AND VEHICLE PREPARATION OK COMPLETED
4 GD&T OK COMPLETED
5 IMS OK COMPLETED
6 PROBLEM SOLVING TECHNIQUE OK COMPLETED
7 METROLOGY OK COMPLETED
8 TIE OK COMPLETED
9 PLM OK COMPLETED
10 7QC OK COMPLETED
11 LOTUS NOTES OK COMPLETED

KAIZEN-I
Before : After :
Earlier, the 3D Collat of Rotary Cutting Machine was Now, i've made a proper tool with two pin inserts
opened with the help of a nose plier.The procedure was that helps to open 3D collat safely , quickly &
too risky,time consuming & improper. more importantly , in a proper manner.
3D COLLAT

KAIZEN-II
KAIZEN-II
Before : After :
Earlier , the smaller tubes with lengths of 45 mm ,50 Now, we have made a proper tool in which the tube is
mm etc were expanded in a Dia expansion machine by placed which is then connected to the stopper.
hand only.

KAIZEN-III
KAIZEN-III
Before : After :
Earlier , the smaller tubes were bended in the bending Now,we have made a proper tool inside which the tube
machine in an improper manner exposing the fingers is kept keeping the operators fingers totally out of
to huge risks. danger.

FINGER

Learning During The Period
1. Proper Understanding Of Automotive Air Conditioning and Product
Awareness.
2. Hands on experience on all stations in production.
3. Learning the basic and critical parameters, importance of pokayoke

(error-proofing) for each respective station.
4. Basic understanding of Time study , Line study etc..
5. Basic awareness about functioning of each department & their

collaborative work.
6. Exposure to Red Bin Area,LRR , Hourly report etc.

Project Identification & Reason
TOPIC SECTION
1. Reduction of Kinematic Operating Torque in Xenon LHD HVAC Production - HVAC

Reason-Customer Complaint
2. To improve the overall brazing process in terms of Production-Tube

Liquid
increasing productivity,better quality,reduction in cost
& less fatigue.
Reason-Increase in in-house rejection
3. Minimization of drawing error R&D

Reason-Very high no. of drawing error at Pune plant.

Case Study
Reduction of Kinematics Operating

Torque in Xenon LHD HVAC

A P
C D
Case Study : Reduction of Kinematics Operating Torque in Xenon LHD HVAC
Team Formation : Mr Suneeth Kr. Behera( Team Leader – R & D)

Mr Neiseituo Sharma ( Team Member – SQA)
Mr Kanish Reddy (Team Member – R&D)
Mr Murali ( Team Member – R&D)
Mr Hruday Ambati( Facilitator)
Problem Description :
Xenon LHD HVAC Kinematics Operating Torque of Air Mode Cam 646580-1250-0-L not qualifying
to standard – 100% cam found with Torque more than 8 kgf-cm on inspection during the period
May’13 .
Old Cam is being used now to feed the Production line.My project is to work on the new cam to bring
the torque value to 4 kgf-cm max.
Start Date : 27.12.13
Target Date : 27.02.14

A P
C D
Data Collection :
Data collected for the months of

May’13 & Jan'14,Feb'14.
Current Occurrence : 100 %

Target Occurrence : 0 %
Benchmarking :
Benchmarking done with existing models & platforms.

S. No Benchmark Model TORQUE (Avg) Difference
1 X3 2.356 kgf-cm Plastic , major design

change , lever design,control
panel
2 DICOR CRAIL/DLX 1.78 kgf-cm/2.09kgf-cm Design changes
3 Safari No load – 4 , 4 Servo motor,design change

With Load – 6kgf-cm , 5.6kgf-cm
4 DLX
2.09 kgf-cm Design change

Change Points :
Sl. No. Change Points
1. Length of Control Cable changed.

Inner length changed from 325 to 335 mm .
Sleeve length changed from 242 to 250mm.
3 Boss dia changed to it's specified dimension of

8.95(mean) which was earlier 0.03+with respect to
it's specs.
2. Design of Cam & the way it is fitted into the HVAC .

A P
C D
Problem Illustration :
Kinematic operating torque of SPRINT LHD coming out to be more than 8.

QC Tool : Cause & Effect Diagram – To identify the probable causes for A P
an effect C D
Cause & Effect Diagram

Machine Man
Boss Dia less
Warpage on on mould case No cut part
the mould on bushes
Unskilled operator
Improper modification
Flashes on of upper case
Cam Design Modification
damper dia
New operator
Flashes on the mould Faulty
restricticg movt. of damper Improper torque on nuts
Torque Gun & bushes
Grease applied
improperly
Kinematics Operating
Height/Depth of Torque more
Control Panel Torque boss dia parts Changed shaft
more Sharp edges on position incorrect
Material of
Control Cable the cam
Bush Dia of the Cable Height
Damper dia on
supporting lever mould case
Material of Cam Slot Width
NG
cam Damper shaft dia
No proper testing
method at input
Friction between CD of cable
Cam design Improper kinematics between lever-
damper ends and
Supporting change I & lever-II
damper ID
lever NG
Material Method

Significance Test – To Check & identify potential significant A P
causes for an effect C D
Test for Significance :

S. No Probable Cause Significance test Result
1 Control Panel Control Panel torque verified & found Insignificant

Torque more Ok as per specification.
Measured by torque-meter .
Operating Torque :
With fitment = 1.8+-0.4 kgf-cm
Actual (with fitment)=2.1kgf-cm
2 Control Cable CD. Control Cable CD verified and found Insignificant

Ok.
Verified by CMM(Co-ordinate
Measuring Machine).
Specs : 325-345mm
Actual : 340.9 mm
U:\GET\SUNEETH\control cable drw
ng.PNG

3 Boss Height of blower Boss Height measured and Significant

outer found NG.
Measured by boss height gauge
Specs : 2.7-2.8 mm
Actual:2.64-2.85
U:\GET\SUNEETH\report1.jpg
4 Damper hole Damper hole ID measured and Significant

dia( inner) found NG.
Measured by Standard Pin
Specs :Dia 4.85-5.05
Actual:Dia 4.71-4.86

5 Outer Boss Dia Outer Boss Dia measured and Significant

found NG.
Measured by digital micrometer
.
Specs : 8.89-8.99
Actual :8.81-8.95
U:\GET\SUNEETH\report1.PN
G
6 Warpage Warpage measured and found to Significant
be significant.
Measured by Slip Gauge.
Specs : 0
Observed : 2.04-3.5
U:\GET\SUNEETH\report_2.P
NG

7 Cam profile variation , Measured by CMM & scanning Insignificant

slot width thickness & with the help of IGS data &
sharp edges . found to be OK.
U:\GET\SUNEETH\1
250left.PNG


8 Cam design Insignificant
modification Checked by the design team &
found to be working properly.

9. Cam supplied by Cam checked & Insignifican

supplier not as verified .Some
per specs. t
dimensions coming
NG but insignificant.
Measured by CMM .
Observed : 8.5 kgf-cm
10. Cam tightening Measured by
more Torque-meter
Specs:8-14 kgf-cm
Actual: 10-11 kgf-
cm
11. Boss height from Measured by Digital Height Significant

surface Gauge .
U:\GET\SUNEETH\report_2.PNG
Specs: 99.8+-0.3
110.4+-0.3
99.8+-0.3
12. No cut part in the Visual Observation .

bushes .
Insignificant

13.
Damper shaft dia Measured by Digital Insignificant
Micrometer.
Specs:4.92-5.02
Actual:4.97mm

QC Tool : Cause & Effect Diagram – To identify the probable causes for an effect

Machine Man
Boss Dia less
Warpage on on mould case No cut part
the mould on bushes
Unskilled operator
Improper modification
Flashes on of upper case
Cam Design Modification
damper dia
New operator
Faulty
Improper torque on nuts
Torque Gun & bushes
Flashes on the mould Grease applied
restricticg movt. of damper improperly
Kinematics Operating
Height/Depth of Torque more
Control Panel Torque boss dia parts Changed shaft
more Sharp edges on position incorrect
Material of
Control Cable the cam
Bush Dia of the Cable Height
Damper dia on
supporting lever mould case
Material of Cam Slot Width
NG
cam Damper shaft dia No proper testing method at
input level
Friction between
CD of cable Cam design Improper kinematics between lever-
damper ends and
Supporting change I & lever-II
damper ID
lever NG
Material Method

A P
REPORT OF BLOWER OUTER CASE (616252-0680) C D

A P
C D
Selection & Implementation of Corrective Actions :
S.N Root Cause Reason Corrective T/Date Status

Action
Undertaken
1 Flashes observed Improper cooling due to Cooling line 07.02.14
in hole. blockage. cleared.
2 Boss Height out of Moulding not conforming as Drawing 10.02.14

specs. per drawing. changed to
accommodate
new specs.
3 Fitment distance Case Warpage due to Cooling time

NG, as a result shrinking caused by a state of increased . 18.02.14
mounting is higher temperature.
problematic.

MONITORING EFFECTIVENESS
Kinematic Operating Torque

INSTRUMENT STUDIED DURING THE PROJECT :
STANDARD PIN DIGITAL HEIGHT CMM PUSH & PULL

GAUGE GAUGE
SLIP GAUGE DIGITAL VERNIER DIGITAL TORQUEMETER

CALLIPER MICROMETER

A P
PROJECT-II C D
CASE STUDY : To improve the overall brazing process in terms of increasing

productivity, better quality, reduction in cost & less fatigue.
TEAM MEMBER -
Suneeth Kr. Behera (Team leader -R&D)
Nitin Minz(Team Member-Production)
Jyoti Ranjan Sahoo(Team Member -Tool-room)
Ravindra Nagare(Team Facilitator)
PROBLEM DESCRIPTION: There were huge number of rejections being reported in the Tube
Liquid Line, majority of which were coming from brazing operation (almost 50%) as a result of
which , we had to bear huge costs, wastage of time & money, wastage of work and subsequently the
end product gets delayed. My project is to reduce it by 50%.
Start Date: 20.08.13
Target Date: 20.11.13

A P
ACTIVITY PLAN C D
('13) ('13) ('13) ('13)

THEME OF THE PROJECT
 PRODUCTIVITY IMPROVEMENT.
 QUALITY IMPROVEMENT.
 FATIGUE REDUCTION.
 COST SAVING.

A P
STEPS TAKEN C D
 SMALL SIZE
 MULTI-FIXTURE
 CONNECTOR POKA YOKA
 DESIGN CHANGES (MANY TYPES )
 WEIGHT REDUCTION

BRAZING PROCESS
Filler rod
Tube
Brazing Fixture
Brazing Torch

A P
AREA SELECTION : C D
FINDING OUT THE AREA TO BE

FOCUSED FROM TUBE LIQUID LINE :
NO OF REJECTIONS
FROM M/C AREA
MACHINING
AREA
FIND OUT NO OF
BRAZING DEFECTS
BRAZING AREA
IDENTIFY NO OF
DEFECTS AT
FINAL FINAL STAGE
ASSEMBLY
LINE & WATER
LEAK TEST
A P
C D
List of Tube Liquid Line defects contributing to In-house rejection
1. Brazing Rejection
2. Bending Rejection
3. Profile NG
4. WLT NG
5. Insulator length NG
6. Dent & Damage on tube
7. Crack on tube
8. Tube length Not O.K.
9. Others

A P
C D
P A R E T O F O R R E JE C T IO N
800 100
700
600
80
Pe rce nt
500 60
Co un t
400
300 40
200
20
100
0 0
P r o b le m s
Count 379 99 87 49 44 39 31 22 17 28
Percent 4 7 .7 1 2 .5 1 0 .9 6 .2 5 .5 4 .9 3 .9 2 .8 2 .1 3 .5
Cum % 4 7 .7 6 0 .1 7 1 .1 7 7 .2 8 2 .8 8 7 .7 9 1 .6 9 4 .3 9 6 .5 1 0 0 .0

Problem Statement
Problem Statement :
Reduction of Brazing Defects

A P
DATA COLLECTION C D
50
Data Collection : 49
48
Data collected from the months of
Rejection Contribution
47
August'13 to Sept'13. 46
45
44
43
Current Occurrence :50 % 42
Target occurrence :25% 41
40
August September
Month
TARGET
SETTING

Process Flow
INPUT
SPINNING
CHIPLESS CNC BENDING BULDGING INSULATOR ASSY
CUTTING
EXP+CRIMP
WASHING MANUAL BRAZING CLEANING O RING ASSY
WATER LEAK TESTING OVEN DRYING N2 BLOWING FINAL ASSY
FINAL INSPECTION PACKING MOVE TO FG STORE
OUTPUT

A P
Analysis – Cause & Effect Diagram C D
METHOD MEN
VERTICAL
OVERFLOW
OF FILLER
MATERIAL
LACK OF
BRAZING AWARENESS
EXCESS FLUX
ORIENTATION
UNSKILLED
HORIZONTAL OPERATOR
FLUX
DA & O2 PRESSURE
USED
FLAME ADJUSTMENT LOW
WRONG MORALE
PROPORTION OF
O2 & DA
BRAZING
BENDING PROFILE NG REJECTION
BEND TUBE GAP IN TUBE &
FILLER ROD CONNECTOR
TUBE WITH INSULATOR
FLUX BRAZING
OD OF BEND TUBE
FLUX QUALITY FIXTURE
OXYGEN & LOCATING PIN
ACETYLENE CONNECTOR BRAZING TUBE TILTING ON
TORCH FIXTURE
CLEARANCE
BETWEEN
ID OF PRESSURE ( DA & O2 )REGULATOR
CONNECTOR
CONNECTOR
& TUBE
MATERIAL
MACHINE

A P
BRAINSTORMING : C D
Some poka yoka

needs to be done to POINTS OBSERVED AFTER BRAINSTORMING
reduce rejection WITH CFT MEMBERS
Modification in gauge
required for better handling
& portability.
Total No. of Fixtures in which

changes have been made-19
Modification in gauge Modification in gauge
required to improve the required to suit the
Weight Reduction-4 productivity operator.
Multi-Fixture-5
Fixture Modification-7
Poka Yoka-3

A P
C D
S.N Root Cause Corrective Actions Resp T/Date Status
1 No timely inspection List of fixtures with its usage Suneeth/ 15.10.13

of fixtures, mainly frequency has been given to Mahesh
those that are regular Line leader to introduce
in use. timely inspection,.
2 Huge fixture causing Unnecessary material removed from Suneeth 30.10.13
operating & fixture . Reduction in weight.
portability problem.
3 Improvisation to
Fixtures converted to multi- Suneeth
multi fixture & poka
fixtures and poka yoka introduced 05.11.13
yoka to improve
in some of the fixtures..
productivity &
quality

A P
EXAMPLE-1 C D
MODEL NO- 4530
CHANGE POINT : POKA YOKA
Earlier, there was a problem of inside material that occurs after brazing. Some inside material gets
through the inner part of the union. To this union,in the customer end, another tube is fitted , which
in case if some inside material stays won't fit .
Thus , before delivering to the customer , it is here checked in the final by a 'fitment tube ' .
Earlier , the union was fitted in a block whose width was same throughout .
Now , the area is modified as such that a pin is provided that passes through the inner dia of the
union thereby preventing any chance of filler material being present.
Advantage:
1.Reduction in rejection.
2.Quality improvement.

A P
EXAMPLE-2 C D
MODEL NO- 5060

CHANGE POINT : MULTI FIXTURE
Earlier , there used to be single piece brazing at a time . Now ,
we can braze two pieces at the same time .
Advantage :
1.Increased productivity.
2.Time saving.
MODEL NO – 3820
CHANGE POINT: MULTI FIXTURE & REVAMP
Earlier, there used to be a single piece braze at a time and the fixture revamp was
long overdue.
Now along with the revamp of the fixture, an extra pin was added to braze two
parts at a time , thereby doubling its productivity.
Advantage:
1.Productivity Improvement
2.Quality Improvement

A P
C D
MODEL NO - 7020
CHANGE POINT: WEIGHT REDUCTION
At present, the weight of the fixture is too high, as a result the
operator finds it difficult to operate and carry such heavy fixture.
The weight of the fixture is being reduced by removing excess

material from the body. It is been done by proper study and
design changes.
Advantage:
1.Fatigue Reduction
2.Improved Portability.
MODEL NO - 4520
CHANGE POINT:POKA YOKA
Earlier,there used to be a block that acted as a bore counter inside
which union was kept while brazing. Due to brazing heat, the
union gets expanded and stuck inside it. It used to create a
problem while pulling it out.
Now a pin is made over the block that goes through the inner dia
of union. So during brazing, if expansion takes place,it doesn't
create any more problem.
Advantage:
1.Quality improvement
2.Reduction in rejection.

A P
C D
MODEL NO- 5250

CHANGE POINT : FIXTURE MODIFICATION
Earlier , the toggle pin from above was not sitting properly, making the charging port
resting imbalanced.
Hence, for guiding purpose, a toggle pin was inserted from the top to make the part
balance on the fixture.
Advantage :
1.Reduction in Rejection.
2.Quality Improvement.
MODEL NO - 4690
CHANGE POINT : MODIFICATION
Earlier by constant use of the fixture, the resting place of the connector had weared out
and a cavity had opened up, and the place was such that the connector used to move
before brazing and used to stuck there in the cavity after the operation making it
cumbersome for the operator, as a result he has to apply some force to pull it out.
Therefore a proper rest place is made .
Advantage :
1.Proper brazing done .
2.Reduction in rejections.

MODEL NO – 3670,5210
CHANGE POINT: POKA YOKA
Operator couldn’t differentiate between the connectors to be used in the different fixtures, with one being 7.5 mm and the other with
7.10-7.15 mm. Both almost looked the same.
So, a poka yoka was done.
We measured the dia of the bigger connector which was 7.5 mm and a pin was made. This was done because with it we can move
connector with dia 7.5 mm through it but not the smaller one with dia 7.10-7.15 mm.
Therefore, operator can first check the connector by this poka yoka and can prevent himself from committing the mistake.
By this, we were able to reduce rejections by almost 50%.
Advantage :
1. Reduction in rejection

A P
C D
MODEL NO - 7180
CHANGE POINT- WEIGHT REDUCTION
Earlier, there were two huge slabs supporting the upper resting part of the
fixture. The fixture was too heavy to move with a single person. It needed a
trolley or another operators help to move it.
In place of those slabs, we introduced two pairs of rod thereby reducing the
weight by a huge difference.
Advantage:
1.Fatigue Reduction
2.Operator Safety.
MODEL NO - 4050
CHANGE POINT- WEIGHT REDUCTION &
MULTI FIXTURE
Earlier , only 1 job was brazed at a time , now 4 jobs are brazed at a point of
time .
Weight was also reduced , earlier , huge block was there weighing 23 kg
overall but now simple 4 pin type guide-way is provided with total weight
of 3 kg only..
Advantage:
1.Safety
2.Easier to handle
3.Increased productivity

EFFECTIVE MONITORNESS A P
C D

A P
PROJECT-III C D
Case Study : Reduction of drawing error .
Team Formation : Mr Suneeth Kr. Behera( Team Leader – R & D)

Mr Ashraf Mirza ( Team Member – CQF)
Mr Kanish Reddy (Team Member – R&D)
Mr Rajesh( Team Member – R&D)
Mr Somnath Sen( Facilitator)
Problem Description :
Error in CAD drawing provided to CQF has seen a considerable increase in recent times, as high as
49.75%.My objective is to reduce it to 25%.
Start Date : 01-04-14
Target Date : 30-06-14

A P
C D
Data Collection :
Data collected for 2 month for the period

March’14 to April’14.
Current Occurrence : 49.75 %

Target Occurrence : 25 %

A P
C D
Reason for Selection:
1) Higher no. of drawing errors at R&D, Pune plant.

2) No control over drawing errors.
3) No. of issues arising at shop-floor & supplier end.
4) Waste of paper and time in drawing correction.
5) Delay in Project Implementation.
6) Loss of PQCDSME goals.
5) Higher no. of errors in scan and old drawings.
7) Customer Complaints .

QC Tool : Cause & Effect Diagram – To identify the probable A P

Miscellaneous Manpower
Spelling Mistake
Confidence of CAD engineers in CATIA
Wrong drawing
Continuous in PLM New Manpower
Less experience in
change from
CATIA
customer Less no. of CAD engineer
Repeated Errors Improper

Sheet format & Communication
tolerance table
Reference drawings
should be updated
Drawing Error More
No prior Training
SAP knowledge
Subros Design Process Continuous change

Not checking all the from CQF
errors at one time
GD & T New implementation
Team-center
Knowledge from CQF
Product
Knowledge Wrong drawing BOM
Drawing
Knowledge
Training BOM & CQF

QC Tool : Cause & Effect Diagram – To identify the probable A P

Miscellaneous Manpower
Spelling Mistake
Confidence of CAD engineers in CATIA
Wrong drawing
Continuous in PLM New Manpower
Less experience in
change from
CATIA
customer Less no. of CAD engineer
Repeated Errors Improper

Sheet format & Communication
tolerance table
Reference drawings
not updated
Drawing Error More
No prior Training
SAP knowledge
Subros Design Process Continuous change

Not checking all the from CQF
errors at one time
GD & T New implementation
Teamcenter Knowledge
from CQF
Product
Knowledge Wrong drawing BOM
Drawing
Knowledge
Training BOM & CQF

A P
C D
Selection & Implementation of Corrective Actions for root causes:
All the drawing templates have been

1 Drawing Template Suneeth 03.06.14
standardized and kept at a common
& Tolerance Table reference path from where all the CAD
engineers are told to take it from.
2 CQF not checking The problem has been intimated to the Suneeth 03.06.14
all the errors at CQF team as it leads to paper wastage &
one time. increase in no. of drawing error which
otherwise would have been in one sheet
itself.
3 Reference
With consultation from CQF & our
drawings CFT members, all the reference
Suneeth 05.06.14
not updated. drawings have been updated.

A P
C D
All the incorrect drawings that have been

4 Wrong drawing in Suneeth 03.06.14
caught up has been changed in the new
PLM. one and the change has been intimated to
all the CAD engineers.
All the new engineers that are new to this
5 New Manpower work have been given regular advice by Suneeth 30.05.14
the experienced ones. Even CQF team has
been informed to review their initial
drawings in pdf format so that page is not
wasted, in case some error exist .
6 No prior training/
All the experienced designers who have
less experience in been working from last 2 years or above
Suneeth 15.06.14
CATIA has been giving constant help & tips to
new joinees.

A P
C D
Implement Counter Measures:
 Implementing the checking gates.

Preparing & implementing check-sheet for drawing checking.
Training on drawing preparation & PLM.
Hands on CATIA tutorials.
Correcting EBOM as per SAP BOM.
Preparing new 3D & 2D data.
Releasing all child parts before assembly drawing.
Mandatory checking with reference drawing.
Preparing & implementing std. tolerance table & sheet format,notes.

A P
CHECK RESULTS C D
1) Reduction in errors related to

a) Repeated error
b) Drawing format
c) Tolerance table
d) Detail drawing
e) Dimension & materials specification
2) Tutorials have helped to improve confidence level on CATIA
3) Spelling mistake are corrected through checking gates
4) No. of errors reduced to 25%.

PERFORMANCE OF CAD ENGINEERS
APRIL MAY
JUNE

COMPARISON OF PERFORMANCE OF DIFFERENT CAD
ENGINEERS OVER THE PERIOD OF 3 MONTHS
Old CAD Engineers

New CAD engineers

DRAWING REVIEW MECHANISM MADE FOR A P
ALL NEW CAD ENGINEERS C D

A P
STANDARD TEMPLATE MADE FOR ALL THE PARTS C D

A P
CHECK SHEET FOR DRAWINGS PROVIDED C D

REPEATED ERROR A P
LIST OF MASTER
DETAILS C D
DRAWINGS

SL SPEC UPDATED & TABLE MADE FOR A P
TUBE CONNECTOR C D
SL SPEC TUBE CONNECTOR TABLE

MONITORING EFFECTIVENESS

LEARNINGS FROM THE PROJECT:
Knowledge about 3D & 2D in CATIA.

Knowledge of Team-center.
Knowledge of checking gates.
Learning about the whole design process.
Learning about torques,WLT specs etc.
Detailed knowledge about drawing.
Knowledge about the whole HVAC system with piping and
condenser mounting.

Tools & Techniques used
Brainstorming Process Flow chart
Pareto Diagram Checklist
Cause & Effect Diagram Cause Validation
Histogram

Thank You
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REVIEW

Suneeth Kr. Behera

1 DNJP INTRO. OK COMPLETED

© Subros Limited. All rights reserved

© Subros Limited. All rights reserved

© Subros Limited. All rights reserved

© Subros Limited. All rights reserved

© Subros Limited. All rights reserved

3. Learning the basic and critical parameters, importance of pokayoke

4. Basic understanding of Time study , Line study etc..

5. Basic awareness about functioning of each department & their

© Subros Limited. All rights reserved

1. Reduction of Kinematic Operating Torque in Xenon LHD HVAC Production - HVAC

2. To improve the overall brazing process in terms of Production-Tube

3. Minimization of drawing error R&D

© Subros Limited. All rights reserved

Reduction of Kinematics Operating

© Subros Limited. All rights reserved

Case Study : Reduction of Kinematics Operating Torque in Xenon LHD HVAC

Team Formation : Mr Suneeth Kr. Behera( Team Leader – R & D)

Start Date : 27.12.13

Target Date : 27.02.14

© Subros Limited. All rights reserved

Data collected for the months of

Current Occurrence : 100 %

Benchmarking done with existing models & platforms.

1 X3 2.356 kgf-cm Plastic , major design

3 Safari No load – 4 , 4 Servo motor,design change

© Subros Limited. All rights reserved

1. Length of Control Cable changed.

3 Boss dia changed to it's specified dimension of

2. Design of Cam & the way it is fitted into the HVAC .

© Subros Limited. All rights reserved

© Subros Limited. All rights reserved

Cause & Effect Diagram

© Subros Limited. All rights reserved

Test for Significance :

1 Control Panel Control Panel torque verified & found Insignificant

2 Control Cable CD. Control Cable CD verified and found Insignificant

© Subros Limited. All rights reserved

Test for Significance :

S. No Probable Cause Significance test Result

3 Boss Height of blower Boss Height measured and Significant

4 Damper hole Damper hole ID measured and Significant

© Subros Limited. All rights reserved

Test for Significance :

S. No Probable Cause Significance test Result

5 Outer Boss Dia Outer Boss Dia measured and Significant

© Subros Limited. All rights reserved

Test for Significance :

S. No Probable Cause Significance test Result

7 Cam profile variation , Measured by CMM & scanning Insignificant

© Subros Limited. All rights reserved

Test for Significance :

S. No Probable Cause Significance test Result

© Subros Limited. All rights reserved

Test for Significance :

S. No Probable Cause Significance test Result

9. Cam supplied by Cam checked & Insignifican