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2010 Kaizen Challenge

2010 Kaizen Challenge. Pyeongtaek, Korea. BSM for Hyundai Theta-Eng. Plant Profile: Pyeongtaek, South Korea. Establishment : Aug.2002 Land/Floor space : 28,328 m 2 /6,209 m 2 SOP : Oct. 2004 Products : Theta BSM, R-BSM, Tau FEMA

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2010 Kaizen Challenge

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  1. 2010 Kaizen Challenge Pyeongtaek, Korea

  2. BSM for Hyundai Theta-Eng Plant Profile: Pyeongtaek, South Korea Establishment : Aug.2002 Land/Floor space : 28,328 m2/6,209 m2 SOP : Oct. 2004 Products : Theta BSM, R-BSM, Tau FEMA Production plan : 520,000 BSM units in 2010 Sales Target in 2010 : USD48.5 million Employees : 135 Customers: Products: FEMA for Hyundai Tau-Eng BSM for Hyundai R-Eng

  3. Problem Identification from scrap cost in 2010

  4. Definition of Tight Turn [Structure of theta BSM] Tight to turn the sprocket of BSM due to internal interference. Intermediate gear Bearing Sprocket Rotor #1 Balance Shaft Valve Rotor #2 X-fer gear

  5. Kaizen Team Members David Shin Quality Manager SD Kim Quality Egr. Daniel Lee Quality assurance Manager(Team Leader James Yoon Manufacturing Egr SY Ahn Production Egr DS Bae Line Leader

  6. BSM Tight Turn Failure Mode Analysis Non machined input shaft hole in oil pump HSG#2 (Action#2) 9.4% Chips & Particles found inside g-rotor chamber (Action#3) 5.8% The causes of 678 failed BSMs with tight turn G-Rotor interference against Oil Pump HGS#3 after assembly (Action#1) 31.7% Mismatching of true position between Input hole and drive shaft hole 47.6% Others 5.5%

  7. BSM Tight Turn Cause Analysis Chips & Particles found inside g-rotor chamber 5.8% Non machined input shaft hole in oil pump HSG#2 9.4% • Dirty wet gloves • Poor washing condition • of used parts • Clamping jig of Y-AXISof SW machine was not working properly. G-Rotor interference against Oil Pump HGS#3 after assembly 31.7% Mismatching of true position between Input hole and drive shaft hole 47.6% • Burr remaining of HSG#3 • due to old brush • Damaged on HSG#3 by • steel guide post Others 5.5% • Unstable machine capability

  8. Increase brush change frequency for perfect de-burring Brush Apr 14, 2010 • Change brush life (4/14) • Past : 20,000 pcs • Revised : 15,000 pcs Cost of Action = improved by supplier Action #1.1 Improving interferencebetween rotors and housings Burr

  9. Changed steel guide post to plastic coated guide post Coated guide post 1st Apr 16, 2010 2nd Oct 11, 2010 Cost of Action = 100,000 won Action #1.2 Improving interferencebetween rotors and housing Housing surface was damaged by guide bar while loading housing on the pallet of the washing machine. Surface damaged of Housing #3

  10. Changed air cylinder to increase Clamping force Jig Apr 5, 2010 Housing Machined Cost of Action = 200,000 KRW Action #2 Improving non-machined part of Input Shaft Hole Jig Housing Non-machined

  11. Maintain clean work conditions From Apr. ↑Installed used washing machine ←Wearing new Rubber gloves with different color Separate area for rework process→ Cost of Action = 1,700,000 KRW Action #3 Improving cleanness of G-rotor and rotor chamber Chips • Particles and chips from dirty gloves from rework • Particles and chips from insufficient washing of used parts.

  12. # 1 line modification for 6bolts Kaizen Results Trend of ‘Tight turn’ value fault ( Jan to Oct 12, 2010 ) Trend ACTION #1 Phase#2 Phase#1 Kaizen Kaizen

  13. 322,352BSM X 0.17% X120,000Won Total saving 65,760k Won 57,200 USD 0.17% Kaizen Results Cost Saving 1.42% 1.25% Total Invest 2,000,000 Won 1,740 USD After Kaizen Before Kaizen Apr 05 ~ Oct 10, 2010 Jan 1 ~ Mar 30, 2010

  14. Standardization for Input Shaft Hole Machining Added push cylinder working condition on the daily machine check sheet Daily working condition check of pushing cylinder

  15. Standardization for Keeping Cleanness Prepared work instruction

  16. Standardization to prevent G-Rotor & Housing interference Revised control plan by Seoul Industry

  17. Improving plan for mismatched true position between Input hole and drive shaft hole Next Kaizen Challenge • Activities are planed to start 2011 because of lack of capacity with machining equipment. • The machining equipment will be more free once the outsourcing Op. 60is completed by Nov, 2010.

  18. Kaizen Target for Tight Turn Improving machine capability 1.42% 1.25% ‘0’ Defect Next Kaizen Before Kaizen After Kaizen Our challenge will continue to achieve zero defects of ‘Tight Turn’ fault through Kaizen activity.

  19. Thank you!!!!

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