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    Final Review Reza 19 June 2014 PDF

    Uploaded by

    Reza Rahmaputra
    This document details efforts to reduce defects in part 67189-0K030 at the NTC stamping plant. An investigation found 18 defects during trim pierce 1 processing due to issues like mismatched panel radii and dies. Root causes were identified as lack of fitting procedures and specification mismatches. Countermeasures developed and implemented included die repairs, making a panel fitting SOP, and trial repairs. This reduced defects from 18 to 3 and improved accuracy from 76% to 96%. Monitoring and standardization efforts will continue for further improvements.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Final Review Reza 19 June 2014 PDF

    Uploaded by

    Reza Rahmaputra
    158 views1 page
    This document details efforts to reduce defects in part 67189-0K030 at the NTC stamping plant. An investigation found 18 defects during trim pierce 1 processing due to issues like mismatched panel radii and dies. Root causes were identified as lack of fitting procedures and specification mismatches. Countermeasures developed and implemented included die repairs, making a panel fitting SOP, and trial repairs. This reduced defects from 18 to 3 and improved accuracy from 76% to 96%. Monitoring and standardization efforts will continue for further improvements.

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    Final Review Reza 19 June 2014.pdf

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    This document details efforts to reduce defects in part 67189-0K030 at the NTC stamping plant. An investigation found 18 defects during trim pierce 1 processing due to issues like mismatched panel radii and dies. Root causes were identified as lack of fitting procedures and specification mismatches. Countermeasures developed and implemented included die repairs, making a panel fitting SOP, and trial repairs. This reduced defects from 18 to 3 and improved accuracy from 76% to 96%. Monitoring and standardization efforts will continue for further improvements.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    158 views1 page

    Final Review Reza 19 June 2014 PDF

    Uploaded by

    Reza Rahmaputra
    This document details efforts to reduce defects in part 67189-0K030 at the NTC stamping plant. An investigation found 18 defects during trim pierce 1 processing due to issues like mismatched panel radii and dies. Root causes were identified as lack of fitting procedures and specification mismatches. Countermeasures developed and implemented included die repairs, making a panel fitting SOP, and trial repairs. This reduced defects from 18 to 3 and improved accuracy from 76% to 96%. Monitoring and standardization efforts will continue for further improvements.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    Reduce Defect Accuracy IMV 5 Model by Eliminating Problem NTC

    Stamping Part 67189-0K030 Reinforcement Back Door Stay

    Name

    : Reza Rahmaputra

    Date Of Entry

    : 02 September 2013

    No.Reg

    : 1324394

    Department

    : Vehicle Quality Prod. Engineering

    Section

    : Vehicle Quality and Planning

    TMMIN VISION 2014

    DIVISION KPI

    To be the Best and the Most


    Flexible in Asia Pasific

    Zero Defect Outflow To


    TMMIN

    A. TMMIN PART CHAIN MAP

    ->

    Project Management & Control

    Toling Progress & Control

    Tooling Technical Support

    Quality & Accuracy Approval


    Quality & Accuracy Achievement

    ->

    No

    Item

    Accuracy
    Target (%)

    Confirmation
    Vehicle (CV)

    95

    Soukaku (SKK)

    2
    3

    Goshi (1W)

    100

    Accuracy Achievements Target


    100
    90
    80
    70
    60

    85 86

    76

    10-12

    1-3

    TOOLING KICK OFF

    4-6

    7-9

    10-12

    1-3

    4-6

    Goshi

    Soukaku

    7-9

    Mass Product
    Trial ( MPT)

    10-12

    Qty Defect

    100

    MPV

    112

    Rank
    17

    CV'Feb

    Week IV' April Soukaku

    59

    0
    Defect Surface Defect Accuracy

    Defect Spot
    Weld

    16

    (14 DA)

    12
    8

    CV

    Accuracy
    (Trimline,Aspec
    Surface, Hole
    Position)

    Part Surface

    Rank

    No Defect Outflow

    Rank

    Week IV'April Soukaku

    Provide Good Quality, Good Process,


    Achieve Production Volume & No Delay

    Current Condition

    By Where

    Problem

    59 DA at NTC

    59 Defect Accuracy on
    CV Activity (February
    2014)

    By Category Part
    35 DA at
    Stamping Part

    By Part Number
    18 DA at R/F Back door
    Stay (67189-0K030)

    Items

    Qty Problem

    Trimline

    Aspec Surface

    Hole Position

    Appearance

    Total

    0 DA at Others
    Supplier

    Pareto Diagram

    16

    24 DA at Sub Assy
    Part

    10 DA at R/F Quarter wheel


    House (61671-0K020)

    7 DA at Hood S/A, Hood


    Lock (53831-0K050)

    12
    18

    10

    0
    61671-0K020

    53831-0K050

    13

    18

    67189-0K030 R/F Back Door Stay

    Part

    Trim Pierce 1
    Dies NG

    Gap

    Fitting Panel
    NG

    Radius Panel x Radius


    Dies Unmatch

    Dies Process Trim


    Pierce 1 Repaired
    (Setting)

    February
    II
    IV

    PIC

    March
    II III IV

    April
    II III IV

    Trimline Plus Ilustration

    Act : Radius Panel < Radius Dies


    Std : Radius Panel = Radius Dies

    May
    II III IV

    AA
    SURFACE
    (-)
    STD : 0.5
    (+)
    ACT : +0.8

    Part
    (-)

    BA

    June
    II III IV

    Schedule
    July
    II III IV

    Aug
    II III IV

    : STD
    : ACT

    Lower
    Dies

    TRIMLINE PLUS
    STD : 0.7
    ACT : +1.5

    Sept
    II III IV

    Oct
    II III IV

    Nov
    II III IV

    Dec
    II III IV

    Die Repair 3

    Trial and Repair 2

    Trial and Repair 3

    Judgment

    Soukaku
    Activity

    Judgment

    Result and Feedback

    No SOP For Panel


    Fitting

    Upper
    Dies

    STOPPER
    PAD

    Accuracy Achieved 96%


    and SOP Implemented

    Defect Accuracy Investigation


    Die Repair 2

    NTC Dies
    Maintenance
    (Baharudin),
    VQPE (Reza)

    : STD
    : ACT

    Lower

    RC #2

    Result

    SOP Compiling and Approval


    Implementation SOP

    Make SOP For Fitting


    Panel

    VQPE
    (Reza),NTC
    (Budi)
    Result and Feedback

    . Aspec Surface Repair


    Upper
    Dies

    Upper
    Dies

    *Defect Accuracy Related :

    Upper
    Dies

    STOPPER
    PAD

    Lower Dies
    LOWER

    Panel Moved When


    Trim Pierce 1
    Process

    Spec Material
    Equal with
    standard

    Radius Panel x
    Radius Dies
    Unmatch

    Countermeasure

    . Trimline Minus Repair

    Panel Not
    Fitting

    Machine

    ()

    Defect Accuracy IMV 5 Model 59 DA on CV


    Activity (February 2014)

    Panel Moved

    (+)

    ( and )

    Defect Accuracy IMV 5 Model 59 DA on CV Activity


    (February 2014)

    Trimline Minus Ilustration (, and )

    Panel not Fitting Ilustration ()

    Material

    Inefficiently
    Fitting Panel

    Root Cause

    Rank

    GAP

    STEP 2 BREAKDOWN THE PROBLEM

    1W

    DIES

    MP
    Experience
    Level 3

    * DA = Defect Accuracy

    Defect Accuracy IMV 5 Model 0 DA on CV Activity


    (February 2014)

    Ultimate Goal

    STEP 5 DEVELOP COUNTERMEASURE AND COUNTERMEASURE

    Spot
    Weld

    Burry,Marking,Kaji
    ri and Emboss

    R Panel < R Dies

    Notes :
    MP : Man Power
    SOP : Standard of Procedure
    NG : Not Good
    RC : Root Cause

    STEP 4

    Reduce 14 DA and
    Accuracy Achievement 95%
    From NTC Stamping Part
    Reinforcement Back Door
    Stay (67189-0K030) in
    Trim Pierce 1 process until
    week IV April 2014

    Defect Decrease Target

    18

    20

    RC #1

    Ideal Condition

    STEP 1 CLARIFY THE PROBLEM

    Defect Accuracy

    Problem Founded

    1W

    No SOP For
    Panel Fitting

    STEP 3

    STEP 2

    Check by
    Proto and
    Designer

    Key Point :

    Methods

    Form Ability
    (Crack,
    Shiwa and
    Nobi)

    Proto Check

    Check by
    Inspector

    Cam Pierce

    Man

    CV FEEDBACK AND REPAIR

    STEP 1

    Rank

    67189-0K030

    Flange

    18 Defect Accuracy From NTC Stamping


    Part Reinforcement Back Door Stay
    (67189-0K030) in Trim Pierce 1 Process

    All Accuracy CV Part


    Achieve by TMC Proto
    with Feedback : Need
    level Up and No
    Handwork For Soukaku
    (SKK) Activity.

    F. STEP HOW TO REPAIR

    Rank

    y7

    Cam Pierce

    Actual

    2015

    CONFIRMATION
    VEHICLE (CV)

    E. CV PREPARATION PROBLEM FOUNDED

    Inspection
    Process

    Target

    2. Soukaku (SKK) is Trial Confirmation activity both press part and weld tooling.

    Reza R.Putra

    100

    95

    95

    1. CV Preparation : All CV Part From Supplier Checked Quality and Accuracy Achievement by TMC Proto

    20

    Muh.Anhar K

    STEP 3 SETTING TARGET

    85

    *Notes :

    50

    Trim Pierce
    1

    Forming

    Before CV

    2014

    CV PREPARATION

    150

    Ndaru J

    STEP 4 ROOTCAUSE ANALYSIS


    7-9

    FMC

    Nicholas A

    Cutting
    Cutting

    Lower
    Dies

    Lower
    Dies

    STANDARD OPERATION PROCEDURE (SOP)

    NO : SOP-DB00-2301

    PROCESS
    PANEL FITTING

    TANGGAL
    : 30-04-2014
    REVISI
    : 0 KE
    HALAMAN
    : 1 dari 1

    NO FAKTOR

    Cutting
    Cutting

    Add
    Weld
    Add
    Weld

    . Making Procedure For


    Fitting Part

    Add
    AddWeld
    Weld

    M
    Q
    Q
    M
    Q
    Q
    Q
    Q
    M
    M
    Q
    Q
    Q
    Q
    Q
    Q
    Q
    Q
    Q
    Q
    Q
    Q
    Q
    Q

    LANGKAH KERJA
    1.0 Ambil panel buat panel fitting
    1.1 Taruh panel diatas die yang akan di panel fitting
    1.2 Beri tanda pada panel dengan spidol cat
    1.3 Bawa panel ke lokasi mesin plasma
    1.4 Lobangi panel yang diberi tanda dengan spidol cat
    1.5 Bawa panel dekat dienya yang mau di panel fitting
    1.6 Ambil gerinda pada tempatnya
    1.7 Rapikan hasil plasma dengan gerinda
    1.8 Kembalikan gerinda pada tempatnya
    1.9 Bersihkan panel dari kotoran
    2.1 Ambil akaipaint dan kwas pada tempatnya
    2.2 Oleskan panel bagian yang penting dengan akaipaint
    2.3 Kembalikan akaipaint dan kwas pada tempatnya
    2.4 Ambil tanah liat pada tempatnya
    2.5 Perhatikan bagian yang penting
    2.6 Taruh panel diatas die yang akan di panel fitting
    2.7 Ketok panel dengan tangan atau tangkai kwas
    2.8 Angkat panel
    2.9 Panel taruh tempat yang aman
    2.9a Ulangi step kerja no:1.9 hingga 2.9
    2.9b Hingga bagian penting atarinya benar-benar rata
    2.9c Gosok bagian atari
    2.9d Sanding bagian-bagian yang kurang penting
    2.9e Die selesai proses panel fitting

    DEPT
    SECT.
    LINE

    DISAHKAN

    : TM
    : DAT
    : T/O

    DIPERIKSA

    DEPT. HEAD SECT. HEAD

    HAL PENTING (KEY POINT)


    -Ambil panel proses sebelumnya
    -Perhatikan model panel terhadap Lwr die
    -Tandai bagian panel yang bersentuhan
    -Gunakan Dolly
    -Gunakan mesin plasma untuk melobangi
    -Gunakan Dolly dan taruh tempat yg aman
    -Gunakan gerinda sesuai kebutuhan
    -Panel sebelum di panel fitting harus rapi
    -Taruh gerinda pada tempatnya
    -Gunakan majun hingga bersih
    -Campuran Akaipaint harus rata
    -Oleskan panel yang bersentuhan dng model die
    Taruh Akaipaint Pada tempatnya
    -Tanah liat warna merah
    -Beri tanah liat sedilit bagian yg penting/ kijun
    -Panel jangan sampai rusak / penyok
    -Ketok panel secara pelan pelan
    -Angkat panel berdua apabila panel ukuran besar
    -Gunakan cover
    -Ulangi step kerja1.9 s/d 2.9
    - Atarinya rata dan panel tidak labil/goyang
    -Gunakan batu gosok #80,#120
    -Gunakan gerinda sanding
    Die siap Pad Awase

    DIBUAT

    LINE HEAD

    ILUSTRASI
    1

    Part Forming
    yang OK

    : OK : NG

    Point Check

    OK
    59

    Defect Decrease Result


    18
    20
    15
    10
    3
    5
    0

    96

    100

    86

    90

    76.6

    80
    70

    Before CV

    CV'Feb Week IV'April

    CV'Feb

    Week IV'April

    * Contributed to the Gap Condition : (15/59)*100%= 26% Reducing Defect

    STEP 6 MONITORING RESULT


    Before Repair

    Accuracy Achievement
    Accuracy (%)

    IMV 5

    Nandy J

    Problem to Tackle:
    18 Defect Accuracy from NTC Stamping Part Reinforcement Back Door Stay (67189-0K030) in Trim Pierce 1 Process

    : Main
    : Support

    2013

    LEVEL

    Prepared by

    Point of Occurence

    D. PROJECT MILESTONE
    MODEL

    Checked by

    C. QUALITY PERFORMANCE INDEX

    TMMIN
    Supplier
    PUD VQPE

    ITEM

    Supplier

    "0" Defect Outflow

    B. PRODUCTION ENGINEERING ROLE

    TMMIN

    JOB RESPONSIBILITY
    Part Accuracy and Quality
    Management

    Approved by

    Stamping Process

    Blanking

    DEPT. KPI

    Acknowledge

    Case (Defect)

    Division
    : Prod.Eng Division
    BACKGROUND

    Flow Process:

    Acknowledge

    Case (Defect)

    PT. TOYOTA MOTOR MANUFACTURING INDONESIA


    PRODUCTION ENGINEERING DIVISION
    VEHICLE QUALITY PRODUCTION ENGINEERING DEPT.

    NG
    18

    Total : 77

    Accuracy

    76%

    After Repair

    : OK : NG

    Point Check STEP 7 STANDARDIZATION

    OK
    74

    NG
    3

    Total : 77

    Accuracy

    96%
    No Handwork ( Full
    Dies Output)

    5W1H
    Item

    WHY

    Panel Fitting No Mistake when


    Procedure
    fitting part

    WHAT

    WHEN

    WHERE

    WHO

    HOW

    SOP

    Try out Activity

    NTC Plant

    Operator

    Fitting Part
    Confirmation

    STEP 8 NEXT ACTION


    >Follow Up Level Up Activity 67189-0K030 Until Soukaku Activity
    >Reduce Defect Accuracy at Reinforcement Quarter Wheel House
    0K020)

    (61671-

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