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WEL COME TO TATA TOYO RADIATOR - PowerPoint PPT Presentation


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Introduction. WEL COME TO TATA TOYO RADIATOR. Area – 7 Acres Manpower of company – 700 nos Turnover - 420 Cr. (Target 620 Cr. For 2010-2011). Continued…. Customers. OUR PRODUCTS. HEATER CORE – CABIN HEATING. Intercooler. RADIATOR – ENGINE COOLING. ENIGNE COOLING SYSTEM. Our Team.

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Presentation Transcript
slide1

Introduction

WEL COME TO

TATA TOYO RADIATOR

Area – 7 Acres

Manpower of company – 700 nos

Turnover - 420 Cr. (Target 620 Cr. For 2010-2011)

slide2

Continued…

  • Customers
slide3

OUR PRODUCTS

HEATER CORE – CABIN HEATING

Intercooler

RADIATOR – ENGINE COOLING

ENIGNE COOLING SYSTEM

slide4

Our Team

Satish Pansare

Ajay Bhosale

Guide

Uday Raut

slide5

Project title

To reduction in Internal Leakage of Tata cub radiator

From 0.83% to 0.43%

Time period - Oct 10 to Jan 11

Project Selection Date-25 Nov 2010

slide6

Data collection

Tata Cub radiator Leakage data from Oct-2010 to Dec-2010

slide9

Process flow of Radiator Clinching

1

2

Bottom tank side nail clinching

Bottom tank Edge nail clinching

4

3

Top tank Edge nail clinching

Top tank side nail clinching

slide10

Details of Tata cub Radiator Assembly

Tata cub Radiator assembly

Top Tank

Pressure cap

Clinching area

Core

Core Support

Drain cock

Bottom tank

slide11

Defect Description

Radiator Leakage area edge clinching

Defect

slide12

Cause & effect diagram for defect Clinching Leakage

Machine

Man

Is the specified M/C used ?

Is operator trained ?

Is it due to improper handling

M/C Setting parameters

Is operator temporary ?

Is M/C in good condition ?

Is it due to improper Rework ?

Radiator Leakage

Header plate nail height ?

Clinching tool

Are Control Plan followed ?

Tank flatness ?

Tank pusher

Method

Material

Tooling

slide13

Root Cause analysis for defect Clinching Leakage

Machine

Man

Radiator Leakage

Clinching tool

Tank flatness ?

Tank pusher

Method

Material

Tooling

why why analysis
Why-why analysis

Why-why analysis for caused 1 – Clinching tool

slide15

Identified cause & action

Cause no. 1

Slot is given at the center of tool. At the time of edge clinching job get shifted & nail not clinch by tool properly.

Due to this problem of half clinching, nail cut & job get leak.

Action

Slot of tool is filled with welding. At the time of clinching resting area of tools get increased & clinching is get properly.

Given solution implemented on 25.12.2010

slide16

Continued…

Action for model :- Tata cub

On Edge clinching tool slot is available

Slot is filled with welding

slide17

Continued…

Action taken for model :- Tata cub

Nail open

OK clinching

After filling of slot

why why analysis1
Why-why analysis

Why-why analysis for cause 2 – Tank pusher

slide19

Identified cause & action

Cause no. 2

Tank pusher is flat at bottom side due to this uniform pressure not apply on tank.

Action

Tank pusher is modified for uniform pressure.

Given solution implemented on 25.12.2010

slide20

Continued…

Action taken for model :- Tata cub

Tank pusher is flat at bottom

Tank pusher is modified for applying uniform pressure on both end of tank

Profile added

Flat side

slide21

Continued…

Changeover part

modified

why why analysis2
Why-why analysis

Why-why analysis for cause 3 – Tank Flatness

slide23

Continued…

Cause no. 3

Tank Flatness

Action

1) Cooling fixture is modify by changing toggle size & toggle position.

Given solution implemented on 27.12.2010

slide24

Continued…

Plastic tank

Toggle

Cooling fixture

slide25

Tangible benefits

Tata Cub radiator Leakage data for 1 Jan to 15 Jan

slide27

Achievement

Rejection reduce from 0.83 to 0.42%

slide28
Improved knowledge

Confidence improved

Stage daring improved

Internal customer satisfaction

In tangible benefits

slide29
After completion of our target 0.83% to 0.43% we select next major defect for Reduction in leakage

Future plans

slide30

Thank you…

Tata Toyo Radiator Ltd.

Survey No.235/245, Village-Hinjewadi,

Taluka-Mulshi,Dist-Pune-411 027.India

Phone No.-+91 20 66524100