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Senator-SS/PC Back to Top. Rotary Knob protruding outside and misalignment Before changeAfter Change Reason: 1.Switch Spindle Tilted. 2.Increased Spindle.

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Presentation on theme: "Senator-SS/PC Back to Top. Rotary Knob protruding outside and misalignment Before changeAfter Change Reason: 1.Switch Spindle Tilted. 2.Increased Spindle."— Presentation transcript:

1 Senator-SS/PC Back to Top

2 Rotary Knob protruding outside and misalignment Before changeAfter Change Reason: 1.Switch Spindle Tilted. 2.Increased Spindle Length. Action Taken: 1. Switch Vendor changed (Shreeji  Ajay switch) Knob tilt (Projected out) Back to Top

3 Screen Printing For Switch positions Before Change After Change Reason: 1. Screen damaged. 2. Artwork constraint Action Taken: 1. New artwork given for change. 2. New screen developed and to be changed after every 10000 nos. or on poor prints Smearing Content cutting the print Content exactly in the print Back to Top

4 Overcutting of Bottom Plate Before ChangeAfter Change Reason: 1. Over cutting of the component during deflashing by the sub-vendor 2. Mixed rejections at vendor end. Action Taken: 1. Segregation of the existing stock at vendor end. 2. Mould of base plate rectified. Poor Deflashing Back to Top

5 Flashes in Vent Area Before ChangeAfter Change Reason: 1. Mould damaged in the vent area and production going on without any consent. 2. Deflashing giving the poor aesthetics Action Taken: 1. Mould rectified for resolving the problem. Flashes in the vent and deflashing giving the poor aesthetics Mould rectified for resolving the problem Back to Top

6 Handle alignment not 90° Before Change After Change Reason: 1. SS jar hole punching offset. 2. Aluminum insert oversized not matching with the SS pot hole size. 3. No fixture in use for Jar assembly. Action Taken: 1.Fixture Implemented for Jar Assembly. 2. Aluminum insert size reduced by turning. Jar Assembly Fixture Back to Top

7 Broken handles and flashes on parting line Before ChangeAfter Change Handle broken and parting line flashes Reason: 1.Problem of sub-vendor end. 2.Old material in stock of PICL purchased by HAC. Action Taken: 1.Segregation of the lot done. 2.Deflashing of the parting line. 3.New handle proposed for permanent solution. Back to Top

8 Lid fitment Tight, Gasket Material poor, lid from unapproved vendor Before ChangeAfter Change Reason: 1.Gasket over size (No drawing available). 2.Over Hardness of Rubber Gasket. 3. Poor finish Natural rubber gasket 4. Local source developed for lid w/o approval Action Taken: 1.Drawing of gasket made, lip size reduced for proper fitment. 2.Hardness defined and controlled in incoming lots of gasket. 3.Proposed for rubber material change Natural  Nitrile. 4.Lid drawing provided and modification done in new supplier part.. Back to Top

9 Filled air release hole in Dry/Wet Lid Reason: 1.Lid from two different vendors PE and Target. 2.Mould of sub-vendor (Target) has smaller hole and is filled. Action Taken: 1.Sub-vendor (Target) mould rectified for the hole size. 2.Material in stock of Target drilled for the required size and flashes removed. Before ChangeAfter Change Back to Top

10 Cut marks and rough finish of Jar Gasket Before Change Cut marks and poor finish of gasket Reason: 1.Old stock lying in PICL damaged due to poor storage. 2.Discipline not followed on production line. Action Taken: 1.Old material scrapped and new jar gasket developed and procured. 2.Training given to all operators for using acceptable material. After Change Proper finish Jar gasket Back to Top

11 Wet Jar Leakage from Jar Gasket area Reason: 1.Aluminium insert oversize 2.Aluminium insert separated from the Jumbo, air gaps between insert and Jumbo. 3.Aluminium insert across flat shape and Gasket of round shape. 4.Nylon washer of round shape and aluminium insert of across flat shape leading to the air gaps. Actions Taken: 1.New rubber jar gasket developed in across flat shape. 2.Temporary : Silicone washer used under the nylon washer and extra size trimmed with special tool. 3.Permanent : Insert moulded jumbo in round insert developed and implemented Silicon gasket trimming tool Before ChangeAfter Change Not OKOK Back to Top

12 Wrong Aluminium insert in use leading to leakage problem Before ChangeAfter Change Reason: 1.Mixing of inserts at vendor end. No drawing of the component available. Action Taken: 1.Segregation done offline at vendor end before assembly. 2.Drawing of the component made. Wrong aluminium insertRight aluminium insert Back to Top

13 Leakage from Jar Handle Before ChangeAfter Change Reason: 1.Mixing of rubber “O” rings 2.0 mm and 4.0 mm at vendor end. 2.Operator not aware of the ring size to be used. Action Taken: 1.Segregation done offline at vendor end before assembly. 2.Photographs of the component shared with the vendor and training given to the operator. 2.0 mm “O” ring4.0 mm “O” ring Back to Top

14 Nylon washer breaking Before ChangeAfter Change Reason: 1.Annealing of the component not done by the sub-vendor. Action Taken: 1.Annealing of the existing done by the vendor. 2.Sub-vendor informed for doing the annealing before dispatch. Back to Top

15 Mixer tripping frequently (due to 1.8A CB) Before ChangeAfter Change Reason: 1.Different CB rating for the same motor of actual wattage 400 W for different model by R & D. Action Taken: 1.Specification revised by the R & D as mixer rating is 500W. Back to Top

16 PC jar cracking Before Change After Change Reason: 1.Initial cracks in the jar (2-3%) while cutting/breaking runner. 2.Aluminum bush holder OD more leading to development of stresses in the bush holder area. Action Taken: 1.Segregation of PC jars before assembly. 2.Bush holder area ID maintained by filing process in the PC jar Back to Top

17 Prince Royal Back to Top

18 Rotary Switch Knob alignment Before ChangeAfter Change Reason: 1.Rotary switch is of local brand in which spindle is tilted. Action Taken: 1.Rotary switch of “Ajay” make of Hindustan Switch used. 2.Operator trained for checking the switch orientation. transition Back to Top

19 Chutney Jar Spillage Before Change After Change Reason: 1.Lid without rubber gasket in use. 2.4 leaf blade creating more pressure leading to spillage of material. Action Taken: 1.Lid design changed and rubber gasket provided. 2.4 leaf blade changed with 2 leaf blade for reducing the pressure. Back to Top

20 Colour variation in top and middle body parts Before ChangeAfter Change Reason: 1.Old stock of PICL. Action Taken: 1.Complete stock at PICL rejected and new material arranged for production 2.Signed reference samples given to HAC. Back to Top

21 Flashes on the control panel Before ChangeAfter Change Reason: 1.Old stock of PICL and problem of molder end. Action Taken: 1.Complete stock at PICL rejected and new material arranged for production and no such observation found. Back to Top

22 Colour and gloss variation in bottom plate Before Change After Change Reason: 1.Mixed, old stock of PICL. Action Taken: 1.Complete stock at PICL rejected and new material arranged for production 2.Signed reference samples given to HAC. Back to Top

23 Lid colour variation Before ChangeAfter Change Reason: 1.Mixed stock in store, different color is for some other brand mixer. Action Taken: 1.Segregation done and acceptable material supplied on line. Back to Top

24 Food Processor Back to Top

25 Scratches in the top area of Mixer/FP unit Before Change After Change Reason: 1.No protection taken on line, rough clothes are in use which gets dirty after some use. Action Taken: 1.Rubber Pad developed for protecting top surface. Back to Top Rubber Pad

26 Spot welding marks on the SS Disc Before Change After Change Reason: 1.Polishing not done after spot welding. Action Taken: 1.Initially polishing process started at HAC end and now it will be done by the sub-vendor. Back to Top

27 Flashes and poor aesthetics of plastic components Before Change After Change Reason: 1.Mould condition very poor and aesthetic quality cannot be controlled with this. Action Taken: 1.New moulds of S-Pusher, D-Pusher and Citrus Filter made. 2.Moulds of centrifugal filter mesh, cone, FP main body and base plate are in process. Back to Top

28 Food Process shaft centre out Before ChangeAfter Change Reason: 1.Uncontrolled process and centering done on hit and trial basis. Action Taken: 1.Go, no go gauge developed for measuring centre. Back to Top Go, No go gauge

29 Belt tension not controlled Before ChangeAfter Change Reason: 1.Uncontrolled process and tension of belt adjusted by skilled operator. Action Taken: 1.A jig developed to control the tension in belt and to maintain consistency. Back to Top Jig for adjusting belt tension

30 Food process switches off if not handled carefully Before Change After Change Reason: 1.A,B,C,D levers existing design not supporting the drop test. 2.Flashes and warpage in the levers. Action Taken: 1.New moulds of lever set developed with improved dimensions to bear the mishandling and drop test. Back to Top

31 Abnormal Sound in FP jars Before Change After Change Reason: 1.Variation in bush ID after ball passing process. 2.Aluminium Jar Base ID less than requirement 15.92 mm. Action Taken: 1.Reaming process to be done to maintain bush ID 15.92 mm. 2.Burnishing tool installed and bush id is maintained by burnishing and not by passing ball or pin. Back to Top

32 Fabio Series Back to Top

33 Flexi lid loose fitment with Dry/Wet Jar Before Change After Change Reason: 1.Air gap between the flexi lid and jars leading to loose fitment. Action Taken: 1.Rubber gasket in grey color developed for this and loose fitment problem resolved. Back to Top

34 Loose/tight fitment of CJ with mixer unit Before Change After Change Reason: 1.Variation in detachable locks. Action Taken: 1.New mold with integrated locks to be developed. Back to Top -Integrated locks to be made in the jumbo -Mould ready, T1 samples awaited

35 Uneven cut marks on control panel and sink mark on bottom plate Before ChangeAfter Change Reason: 1.Uneven cut mark is the gate point and manual cutting error is creating this to uneven shape. 2.Sink mark is due to the mould design. Action Taken: 1.Moulder is taking care while deflashing and results has been improved. 2.Sink mark can’t be removed or minimized due to mould design constraint. Back to Top

36 Issue : Jumbo Breakage in Liquid Jar Before Change After Change Reason: 1.PP material in screw barrel of molding machine got mixed with ABS in a particular lot. 2.Threaded jar of SS and threaded Jumbo of ABS fitted manually so undefined force used for tightening the jars. Action Taken: 1.Design changed, concept of threaded jar and jumbo removed. Regular jar assembly done. Back to Top Jumbo Breakage in Liquid Jar

37 Before Change After Change Back to Top Lid fitment tight of the Small Container Reason: 1.Problem in the mold of the component. Diameter increased at the lid fitment area. Action Taken: 1.Problem discussed with the vendor and sub-vendor and the mold correction will be done. Mould correction in process

38 Cool touch chutney tight fitment with Mixer Grinder Before Change After Change Back to Top Reason: 1.Variation in thickness of rubber ring Action Taken: 1.Incoming inspection of the rubber ring as per the drawing. 2.Jar Matching done on line to avoid tight fitment. 3.Q-point displayed on the production line to take care while Jar Matching. 4.Monitor line rejections for this defective components.

39 LLDP Gasket Cutting Problem Before Change After Change Back to Top Reason: 1.Zero hour problem from vendor end. Action Taken: 1.To ensure incoming inspection of the raw component. 2.In case of any defect, lot will be segregated offline. 3.Q-point displayed on the production line with photographs. 4.Training given to packing operator. 5.Line rejection monitoring to be done.

40 Xylo (MG for scheme) Back to Top

41 Main Body breaking in drop test Before ChangeAfter change Reason: 1.Motor resting points in main body week enough to break on impact. Action Taken: 1.Motor resting area strengthened by increasing thickness and providing material around the motor resting points. Back to Top

42 Carbon Plate Screw Loose Before Change Reason: 1.Carbon plate screw loose and unfastening itself on running the motor. Action Taken: 1.Anabond thread locker implemented for screw fastening. 2.Instructions displayed on the production line for the adherence. 3.Training given to operator to check every bracket before assembly. 4.Screw fastening replaced with riveting as a preventive action. Back to Top After change

43 Before: Sink MarkAfter: Sink Mark not visible Sink Mark on Xylo (KMG50W3S-DBF) body Reason: 1. Under sized sleeves in mould Action Taken: 1. New sleeves made and corrections done in the mold. Back to Top

44 Senator-DX Back to Top

45 Screen printing not aligned with knob Reason: 1.Wrong artwork developed. Action Taken: 1.Artwork modified and problem resolved. Before ChangeAfter Change Back to Top

46 Before ChangeAfter Change Fitment problem of the top and middle unit Reason: 1.Mould replication was done by the vendor and no validations done before TTR1. Action Taken: 1.Mould rectification done by the vendor to minimize the fitment problem but still there is scope of improvement which will be started in next 25-30 days. 2.Operator s has been trained to detect this problem, if any on production line. Back to Top

47 AXE-3S Back to Top

48 Before ChangeAfter Change Bottom Plate and OLP fouling with the motor Reason: 1.Very small mould for 300 Watt motor of 15 mm stack height. 2.Used for 400 Watt motor of 20 mm stack height leading to foul with bottom plate and motor unit. Action Taken: 1.Bottom plate mould rectified to accommodate 400 Watt motor of 20 mm stack height. Motor fouling with the bottom plate OLP fouling with the bottom plate Space created for motor OLP location changed Back to Top

49 JMG-YUVA Back to Top

50 Before ChangeAfter Change San Lid touching with the JMG cutter Reason: 1.SAN lids not interchangeable due to variation in motor coupler height variation. 2.Defective SAN lids replaced by the packing operator during packing without getting matched with the JMG. Action Taken: 1.To maintain coupler height a proposal has been given to reduce no. of washers used under the coupler, which will be implemented in new model YUVA plus. 2.Defective san lid, if any found by the packing operator will not be replaced by him/her, but complete JMG unit will be returned to the tester to match the new SAN lid. Back to Top

51 Aesthetic problems of JMG Before Change After Change Reason: 1.Due to poor condition of moulds, aesthetics getting worst day by day Action Taken: 1.New moulds are taken for new model YUVA plus. Back to Top

52 Electrical Wiring and performance of JMG Before Change After Change Reason: 1.Earlier Soldering was done to connect terminals. 2.2 speed JMG and high RPM 18000 at Juice Action Taken: 1.Soldering replace with Male female crimps 2.3 speed JMG and 1 st Speed RPM reduced with a diode (IN 5408) to increase juice efficiency Back to Top

53 San Jar abnormal noise and jar leakage Before Change After Change Reason: 1.Separate Jar base and bush holders in use and due to misalignment of bush holder with the jar base, abnormal noise accured. Action Taken: 1.Integrated Jar base design recommended and will be implemented in YUVA plus JMG Back to Top

54 Motor Top Unit Aesthetics Before Change After Change Reason: Action Taken: 1.Screw cap colour changed from black to white and material changed to nitrile. 2.Jar support pads reduced in size by changing shape from rectangular to round. Back to Top

55 Flashes in the Mesh Before Change After Change Reason: 1.Due to problem in mould, a flash was there in the mesh. Action Taken: 1.Mould rectified and flash problem rectified Back to Top

56 Geyser Back to Top

57 Improvements planned in the off- season. Before Change After Change Body mismatch in the storage and instant water heater Reason: 1.Market moulds, decision can’t be taken without consent of the vendor. 2.Rectification can’t be planned in the peak season, will lead to supply issue. Action Taken: 1.Vendor has discussed the issues with his vendor and improvements will be done in off season. 2.Specific action plan is to be made with the vendor and sub-vendor. Back to Top

58 Before Change After Change Sub-graded MFV (multifunctional valve) in use with class-1 geyser Reason: 1.Sub graded due to poor design as PRV knob is not locked by screw and settings can be disturbed by rotating. Action Taken: 1.New MFV arranged by the vendor as per our requirement. PRV knob not locked and can be easily removed by rotating anti-clockwise PRV knob locked by screw and design is improved so that it can’t be removed in any way. Back to Top

59 Before Change After Change Wrong BEE label in use Reason: 1.Wrong BEE labels in use by the vendor as manufacturing year printed was 2011 or 2012, but current year is 2013. 2.Consuming its stock as vendor is not aware of the BEE norms. Action Taken: 1.Communicated the vendor with relevant data from BEE website. 2.Arranged new BEE labels and trained their supervisors and operators to use only current year BEE labels. Manufacturing year 2011/2012, but current year is 2013 Manufacturing year 2013 AND current year is 2013 Back to Top

60 Before ChangeAfter Change Multi stickers and stickers on stickers used on products Reason: 1.Pre-printed common rating plates used for all geysers and capacity and standing loss value written by permanent marker and for model name and serial no stickers are pasted on this. Action Taken: 1.New blank labels arranged for the rating plates and printed in house on the thermal label printers (Barcode printers). Back to Top

61 Before ChangeAfter Change Multifunctional valve supplied separately (customer may or may not use this leads to safety issue) Reason: 1.Due to common size box for the class-1 and class-2 geyser, no space for the multifunctional valve in the gift box. Action Taken: 1.Proposed for designing new gift box for accommodating the geyser with the MFV. Back to Top

62 Before Change After Change Tank Leakage Reason: 1.SS-304L tank thickness 0.6 mm and after welding, properties of SS deteriorates and during application contraction and expansion process weakens the welded joint and tank starts leaking. 2.Pressure plate has multi brazing joints which are very poor in strength weakens in application and leakage starts from any of the joints. Action Taken: 1.Glass Lined tanks which has thickness of minimum1.5 mm and MIG welding which has very high strength coated with the viterous enameled inside of DFT approximate 1.5-2.0 mm gives a very long life to the tank and will leak only in exceptional cases. 2.Magnesium anode used along with this also protects the MS tank by filling pin holes in the coating. SS Tanks of thickness 0.6 mm Glass lined MS tank of thickness 1.5 mm Pressure Plate Pressure plate replaced with HE Back to Top

63 Before ChangeAfter Change Thermostat malfunctioning Reason: 1.Stem type thermostat design is very poor and result varies in the range of 10°-12° with the slight variation in the component used in the thermostat. Action Taken: 1.Proposed for use of capillary thermostat which is very precise and results varies only in the range of 1°-2° only Back to Top

64 PCB failure in ICT Prince (Identification) Before Change After Change Reason: 1.Due to imported PCB, there was no control on the components. Action Taken: 1.In-house PCB manufacturing started and for better traceability, manufacturing date mentioned on a temper proof sticker. Back to Top


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