IInd Kaizen Super Turbo

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Kaizen Group PresentationKaizen Group Presentation

Super Turbo GroupSuper Turbo GroupWelcomes You allWelcomes You all



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Organization InformationOrganization Information

Products

Tractors & Engines

Products

Tractors & Engines

Market Leader

in

Tractor Industry since last

23 years

Market Leader

in

Tractor Industry since last

23 years



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Qu ality Jo u rneyQu ality Jo u rney

ISO9001 -A u g us t 1996

Q S 9000 - May 2000

ISO14001 - 2003

Deming Award - Nov.2003

Japan Qu ality Medal ( planned ) - Nov. 2006

Mahindra i s Fir s t Tractor company in the World

to achieve Deming Award



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K aizen Gro u p InformationK aizen Gro u p Information

N ame : - ³Super turbo´

Meeting Frequency:- Weekly every Monday 2.00 PM (1 hr)

N ame of Members :-

Formation : - J un 04

Product unit : - Testing & Evaluation (Product Development Group)

Facilitators : - Mr. Deepak T hakur & Mr. A.D. Kulkarni

Mr. Prakash K. LattooMr. Sanjay K. Patil

Mr. Dinesh Gadekar

Mr. Parag M.Panse - Leader

Mr. Bhushan K. Patil - Dy. leader



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R esolution

Of Engine Failure

Due toLub.Oil Pressure Drop

R esolution

Of Engine Failure

Due toLub.Oil Pressure Drop

C a s e St u dyC a s e St u dy



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S teps Adopted S teps Adopted

Defining the problem

Data Collection for deciding core of the problem

Identification Of Causes

Selection of probable causes

Testing of Probable causes

Developing Solutions

Validating Solutions

Trial implementation

Field Trial & Review

Regular Implementation

Management Review

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In trial batch of newly developed 30 Hp Model, Severe performance

drop observed on 11% tractors during initial 350 Hrs. of usage.

S tepS tep - -11

- Horse power of engine dropped from 30 hp to 22 hp.

- Lubrication oil pressure dropped from 3.12 bar to 0.8 bar.

Background of the Problem

L a u nching of 30 Hp model wa s Stopped



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On the basis of detailed analysis , the problem is defined as ;

Definition of the Problem

³Engine Fail u re d u e to L u b. oil

pre ssu re drop´



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Management Review

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After detail failure analysis of field returned engine, following

major observations were recorded .

Problem reported after initial 350 Hrs. of usage in field

application (Under Hyd Pump Loading.)

Problem reported during field testing of trial batch. 2 tractorsout of 19 were observed defective.

Data C ollection for deciding coreof the problemS tepS tep - -22

1. Crank case first cam bore wear excessive. (144 micron against 15)

2. Cam shaft first journal wear excessive.(90 micron against 15)

3. Valve hitting marks on piston top surface.

4. Both Push rods of first cylinder found bend



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Management Review

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Identification Of C a us e sIdentification Of C a us e sS tepS tep - -33

C ambore oilhole

mi s matched

Ass y Error

C am s haft boltnot torq u ed

No float incam s haftsu b a ss y

Thr us t wa s hera ss y in rever s e

direction

L e ss torq u e val u e of cam s haft bolt

Exce ss ive parent cambore ovality

C am bore u nder s ize

C am s haft dia over s ize

C rankca s e materialnot O K

Exce ss ive cam s haftJr. dia r u n o u t

Exce ss ive cam s haftgear thr us t face r u n o u t

C am s haft thr us theight le ss

Oil s tarvation d u e tole ss oil su pply

30 hp engine de s ign errorcompare with proven engine

De s ign clearancebetween cam

bore & s haft i s le ss

C am bore thr us tface area i s le ss

Engine oil pre ssu rebelow min.

req u irement

C am s haft de s ignedfloat i s le ss

Direct materialcontact

MATERIA L METHOD

MA C HINEMAN

Engine l u boil

pre ssu redrop



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Field trial & Review


Management Review

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Engine l u boil

pre ssu redrop

S tepS tep - -44 Selection of probable ca us e sSelection of probable ca us e s

C ambore oilhole

mi s matched

Ass y Error

C am s haft boltnot torq u ed

Thr us t wa s hera ss y in rever s e

direction

L e ss torq u e val u e of cam s haft bolt

Exce ss ive parent cambore ovality

C am bore u nder s ize

C am s haft dia over s ize

C rankca s e materialnot O K



C am s haft thr us theight le ss


30 hp engine de s ign errorcompare with proven engine

C am bore thr us tface area i s le ss

Engine oil pre ssu rebelow min. req u irement

C am s haft de s ignedfloat i s le ss


MAN MA C HINE

METHODMATERIA L

No float in cams haft su b a ss y

De s ign clearancebetween cam bore

& s haft i s le ss



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Engine l u boil

pre ssu redrop

MAN MA C HINE

METHODMATERIA L

S tepS tep - -44

Ass y Error

No float in cams haft su b a ss y




De s ign clearancebetween cam bore

& s haft i s le ss

Engine oil pre ssu rebelow min. req u irement


Selection of probable ca us e sSelection of probable ca us e s

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Management Review

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S tepS tep - -5 5

Excessive camgear thrustface run out

Checkedfailed engineGearparameter

Withinspecified

limit

Cause invalid

Float valuesverified from

Assy data

No float inCam shaft

sub assy

Testing of Probable causesTesting of Probable causes

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Excessive camshaft journaldiameter run

out.

CheckedValues inAssy

Ob s ervation C oncl us ionC a us e Te s t MethodNo.



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S tepS tep - -5 5

InsufficientDesignedclearances.

Value comparedwith provenengine

Out of

specified

limit

Cause valid

Test comparedwith proven

engine

Oil starvationdue to less

oil supply

Testing of Probable causesTesting of Probable causes

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Mechanicalcontact of camshaft & cambore

Tested underHyd loading


Seizuremarks areobserved on

cam shaft journal

Cause valid

With inspecifiedlimit

Cause invalid

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S tepS tep - -5 5 Testing of Probable causesTesting of Probable causes

With in

specifiedlimit

Cause invalid

Verified from

the testresults

Engine Initial

oil pressurebelowminimumrequirement

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Management Review

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Developing SolutionDeveloping Solution

Brain storming conducted for probable solutions

1) Increase oil supply hole size in cam

bore from 8mm to 10mm.

2) Remove circular groove from cam journal

3) Reduce oil hole size of gear lubricationfrom 3mm to 1mm

S tepS tep - -66

4) Relocation of Oil supply pipe closer tofront cam bore.

Oil starvationdue to less oilsupply

Mechanical

contact of cam

shaft & cam

bore

Probable Sol u tion sC a us eNo.

5

4



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Management Review

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Validating SolutionsValidating Solutions

Propo s ed Sol u tion s

1Increased oil hole size

in cam bore

S tepS tep - -7 7

Modification s Te s t Re su lt sSol u tion



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Increa s ed oil hole s ize in cam bore



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1Increased oil hole size

in cam bore

S tepS tep - -7 7


Elimination of groovefrom cam journal

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Increased oil hole size

in cam bore

Oil hole size reduced infront cover

3

S tepS tep - -7 7



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Oil hole s ize red u ced in front cover



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Increased oil hole size

in cam bore EngineTestingwith Hyd

loading in

lab

Oil Pressure

drop

continued

Oil hole sizereduced in frontcover

3

S tepS tep - -7 7



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Exi s tingArrangement

C am Bore(Oil s tarvation)



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Relocation of Oil supply

pipe closer to front

cam bore.

Final Sol u tion

Validating Final SolutionValidating Final Solution


S tepS tep - -7 7



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Oil starvation due to less oil supply-

Tappet making restrictionto oil flow

Developing Final SolutionDeveloping Final Solution

Details study of oil passages showed Oil passage is getting

partially blocked by tappet coming in front of oil inlet.

70%

Hole Blockage

S tepS tep - -7 7



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Validating SolutionStepStep --88

70% Hole Block 100% Hole Open



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Exi s tingArrangement

C am Bore(Oil s tarvation)

Final Sol u tion

C am Bore(No oil

s tarvation)



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Relocation of Oil supply

pipe closer to front

cam bore.

No Oil Pressure

drop.

Final Sol u tion

Validating Final SolutionValidating Final Solution


C oncl us ion - Oil pre ssu re drop eliminated. Sol u tion effective

S tepS tep - -7 7

EngineTestingwith Hyd

loading inlab



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Management Review

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11 Regular Implementation



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2 nos. Of modified engines are built & tested under newly

designed hydraulic load cycle.

Trial implementation & checkingperformance in laboratoryTrial implementation & checkingperformance in laboratory

T he test results showed N o drop in oil pressure.

Wear of first cam journal & cam bore observed to be w ith in limit

(against 15 microns).

S tepS tep - -88

Successful Endurance test completed.

T he test results showed N o drop in po w er.



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Management Review

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Propo s al pre s ented to the management & they

have approved & al s o highly appreciated

Propo s al pre s ented to the management & they

have approved & al s o highly appreciated

Management ReviewManagement ReviewS tepS tep - -99



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Field Trial & ReviewRegular Implementation

Management Review

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T his improved design is implemented on 19 tractors of seeding

batch in the field.

Subject tractors are tested for different applications in field under

hydraulic load application (Cultivation etc.).

Feedback taken on detail monitoring done for oil pressure drop

& power loss.

Field Trial & ReviewField Trial & ReviewS tepS tep - -1010



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Randomly selected 2nos. Of tractors tested in field out of 19nos.

brought back to plant for conformance of solution.

Conducted lab performance test for power, oil consumption & oil

pressure in as received condition.

Lab performance found well within acceptable limits.

Tear down analysis of engine conducted.

Condition of front cam bore & journal found perfectly OK.

(Wear cam bore - 0.006mm & cam journal - 0.003mm against 0.015mm)

Field Trial & ReviewField Trial & ReviewS tepS tep - -1010



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Follow-up & ReviewRegular Implementation

Management Review

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S u bject improvement i s implemented on prod u ction

batch of 904 no s . tractor s prod u ced till date.

S u bject improvement i s implemented on prod u ction

batch of 904 no s . tractor s prod u ced till date.

Regular ImplementationRegular Implementation

No c us tomer complaint till date

S tepS tep - -1111



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BenefitsBenefits

Produc t la unch e d s ucc essf u lly i n Oc t 2004

E n able d sale 904 no s s o fa r

Save d wa rr a n ty p ro bable co st o f 25,000 pe r t r a c t or Th is h as Imp ro ve d ma rk et s h a r e 30 H P r a ng e t r a c t or

0

20

40

60

80

100

120

140

N o

o f t r a c t o r s

M a y - 0

4

J u n - 0

4

J u l - 0 4

A u g - 0

4

S e p - 0

4

O c t - 0 4

N o v - 0 4

D e c - 0 4

J a n - 0

5

F e b - 0

5

M a r - 0 5

A p r - 0 5

M a y - 0

5

J u n - 0

5

J u l - 0 5

A u g - 0

5

Month

Launching

Planned Actual

% Defect

0 0

11

0

2

4

6

8

10

12

14

M a y

- 0 4

J u n -0

4

J u

l - 0 4

A u g

- 0 4

S e p

- 0 4

O c t -0 4

N o v

- 0 4

D e c -0 4

J a n -0

5

Month

% D

e f e c t

N o e ng i n e fail ur e obse r ve d till d ate

L a u nching Halted

Po ssible C u st ome r d issatisfa c ti on was av o i d e d N ew p roc ess d evel o pe d f or f u t ur e p roj e c t

S olution Developed &

Implemented

D efe c t f r ee p roduc t d evel o pe d bef or e la unch i ng

Warranty Cost (Cam w ear)

0 0

25000

0

5000

10000

15000

20000

25000

M a y

- 0 4

J

u n -0

4

J u

l - 0 4

A u g

- 0 4

S e p

- 0 4

O

c t -0 4

N o v

- 0 4

D e c -0 4

J

a n -0

5

Month

R s . P e

r T r a c t o r



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Competency building in solving problem using Kaizen.

Special Gains to MembersSpecial Gains to Members

S atisfaction for successfully solving critical product development problem.

Upgradation in the product development kno w ledge.

Team spirit has got boosted.



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Future PlanFuture Plan

Resolution of

Of Cam Bush R otation

In

60hp Engine

Resolution of

Of Cam Bush R otation

In

60hp Engine



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The woods are lovely dark & deep And I have promises to keep

And miles to go before I sleep And miles to go before I sleep

-Robert Frost



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V ote Of Thanks

Q C F I (Hyderabad)

&

Q C F I (Mumbai )

V ote Of Thanks

Q C F I (Hyderabad)

&

Q C F I (Mumbai )



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W ish You All

Happy

&

Prosperous New Year

W ish You All

Happy

&

Prosperous New Year



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H ydraulic Loading

Of

Engine

H ydraulic Loading

Of

Engine

Hydra u lic OperationHydra u lic Operation



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Cam Shaft

Hyd Pump

Cam Bore

Documents

IInd Kaizen Super Turbo