Step 1.
Definition of A, B
and C Type defects
Role of the operator is most important in Quality
Management.
While working on the machine operator has to be
very alert Whenever the defect is generated operator
has to analyze the phenomenon and write whether it
is A, B or C type of defect. He has to understand with
what action the defect is eliminated.
Not OK
Example for A Type Defect.
Action taken by the operator.
USL
OK
OK
[Link] put is OK initially.
[Link] NOT OK.
[Link] is taken by the operator.
[Link] OK.
LSL
A type defects are caused by Sporadic Causes.
These defects occur suddenly and will continue till taking
corrective action.
Can be solved through why why analysis.
By taking corrective action the defect can be corrected.
Methodology of solving A Type phenomenon.
Phenomenon
Cause
Countermeasure.
Size variation.
Tool blunt
Provide counter to
facilitate tool changing
Kaizen for Reducing A type defect OD oversize on AS 48.
IDEA: Tool life monitoring
Before
No counter for tool life
monitoring
After
Electronic counter with
Auto machine shut off.
Not OK
Example for B Type Defect.
No Action taken by the operator.
USL
OK
OK
LSL
[Link] put is OK initially.
[Link] NOT OK.
[Link] action is taken by the operator.
[Link] OK on its own.
Not OK
Example for B Type Defect.
No Action taken by the operator.
USL
OK
OK
LSL
B Type defects are generated due to chronic causes.
These defects generate gradually and disappear itself without taking
corrective action.
By taking countermeasures for all the abnormalities this type of defect can be
corrected.
Methodology for solving B Type defects is PM analysis.
Example of B type defect - On AS 48 machine while checking
the OD of the component continuously one component found
oversize when next component is checked it is found OK.
So without action of the operator the machine is producing ok
component on its own.
We can take practical example of defect OD oversize on AS 48
[Link] continuously checking OD of the components
on AS 48 machine first component is OK. During machining
of the second component chip is trapped between component
and tool so the component is not ok during the third
component no chip is trapped so the component is [Link] have
to do PM analysis of the phenomenon.
Not OK
Example for C Type Defect.
Action taken by the operator.
USL
LSL
[Link] put is NOT OK initially.
2. Action is taken by the operator.
[Link] OK. (Setting scrap)
C type defects occurs during set up.
These defects occur in the first product when the set up is done.
By taking corrective action the defect can be corrected.
By providing tool setting master and set up aid this type of
defect can be eliminated.
Methodology of solving C Type phenomenon.
Phenomenon
Cause
Countermeasure.
Size variation.
Wrong setting.
Provide Tool setting master.
Damage.
Measurement error
during setting.
Change analog to Digital.
Kaizen for In-house Rejection C Type Defect : OD oversize
IDEA :Tool setting gauge
Before
No gauge for OD form
tool setting on AS 48
machine
After
Tool setting gauge
provided for OD form tool
setting.
Kaizen for In-house Rejection C type : Lip, undersize
IDEA : Tool setting Gauge
Before
No gauge for Recess tool
setting on AS 48 machine
After
Tool setting gauge
provided for recess tool
setting.
Step 2.
Collecting the data in
A B and C Type from
all the Machines.
QM
Shop:-Rocker Arm Bearing
CELL DEFECT PHENOMENON
20
600
15
15
15
15
15
13
13
15
12
12
12
12
12
12
12
12
12
12
12
12
500
12
12
12
400
284
219
10
201
85
181
199
63
60
52
84
67
29
95
68
46
300
265
230
203
231
200
152
100
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Defect Phenomenon
30
31
32
33
34
35
36
TOTAL QTY
N o .o f D e f e c t
phenom enon
Machine Defect Phenomenon
8
6
4
2
Defect Phenom enon
2
Defect phenom inon killed
0
Face grinding
OD grinding
ID grinding
Machines
Week
15
Month
16
17
18
Def ect Phenomenon
15
15
15
Kaizen-cumulative
Defect-phe nom e non
20
21
22
23
May-05
15
Defect Phenomenon killed
Sr No
19
Apr -05
15
13
13
24
25
26
27
28
Jun-05
29
30
31
32
33
Jul-05
34
35
36
Aug-05
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
Width Undersize (Face grinding)
76
57
10
15
18
10
96
41
35
46
65
194
Width Oversize(Face grinding)
Parallelism NOT OK(Face grinding)
Burning(Face grinding)
18
OD Undersize( OD Grinding)
22
32
18
19
14
50
79
54
11
17
162
21
11
OD Oversize ( OD Grinding)
OD OVALITY( OD Grinding)
13
Flat mark( OD Grinding)
10
14
14
Burning( OD Grinding)
118
17
10
Burning (ID grinding)
10
12
11
ID Oversize (ID grinding)
11
19
39
48
17
40
15
107
10
41
112
24
84
36
82
22
12
ID Undersize (ID grinding)
13
Taper unequal (ID grinding)
61
40
99
14
Damage mark (ID grinding)
15
ID Chatter (ID grinding)
40
42
93
11
26
14
13
219
85
84
201
199
63
52
60
29
67
95
181
46
203
284
68
230
152
265
231
TOTAL QTY
Step 3.
Forming Team and
Doing kaizen for
killing the defect.
Kaizen for killing defect
Phenomenon for
Rocker Arm
Kaizen Idea Sheet
Activity
KK
JH
QM PM SHE OTP DM ET
M
Loss
'
Result area
Kaizen Theme:-To eliminate the Rejection due to flat mark
On OD grinding machine..
Idea :- From power failure to No power failure
Problem More rejection on OD grinding Countermeasure : To provide UPS for running one Bench mark due to flat mark.
Grinding cycle of Spindle after power failure.
Target -
64
0
Kaizen start -
20/05/05
Kaizen finish
Analysis Why flat mark on OD ?
Due to no rotation of Work piece during
grinding cycle
Why No rotation of work piece?
Due to spindle stoppage.
Results Elimination of scrap due to OD Flat
mark.
21/05/05.
Team MMN,VGR,DDC,UPS
Sustaining Kaizen
Why spindle stops running ?
Due to power failure.
Scope for Horizontal Deployment
S.N.
M/C
Target.
Resp Statu
s.
