Professional Documents
Culture Documents
2733
2797 1 2 3
2653 2686
Taping short / 1935 1769
988
Excess / 568 1121
922 1434
1395
1541
Loose/Miss
Apr May June July Aug Sep Oct Nov Dec-08 Jan-09 Feb-09 Mar-09 Apr-09
Clip/Clamps/Grt. 2187 3
5 4
Direction/Position 1249 1078
278 1091
580
wrong/excess/not 238 721 729
545
291
cut Apr May June July Aug Sep Oct Nov Dec-08 Jan-09 Feb-09 Mar-09 Apr-09
Top Internal Defects Trend
Month Wise Def ec t Tr end & Rank
4 3
900 1320
Tube 577 1039 5
641 1023
(V.T/V.S,Cot,Seal,fuse,
381
foam,soldering, sleeve, 404
fuse) missing/NG 262 178
Apr May June July Aug Sep Oct Nov Dec-08 Jan-09 Feb-09 Mar-09 Apr-09
2 1254
Insulator too
short/Wong Cutting
Length 292
Apr May June July Aug Sep Oct Nov Dec-08 Jan-09 Feb-09 Mar-09 Apr-09
Internal Defects Trend: Cutting
Cutting PPM Trend
1400 500.0
1200
400.0
1000
800 300.0
600
200.0
Target PPM = 73
400
100.0
200
0 0.0
Apr-08 May-08 Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09
Crimping PPM
Internal Defects Trend: Crimping
6000 0.14
5000 0.12
0.1
4000
0.08
3000
Target = 0.055
0.06
2000
0.04
1000 0.02
0 0
Apr-08 May- Jun-08 Jul-08 Aug- Sep- Oct-08 Nov-08 Dec- Jan-09 Feb-09 Mar-09 Apr-09
08 08 08 08
ECT DPU
Internal Defects Trend: FVI
FVI Trend: Defects and DPU
7000 0.16
6000 0.14
0.12
5000
1000 0.02
0 0
Apr-08 May- Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09
08
(Corolla)468
(Corolla)464
Rover)507
(Corolla)454
(Corolla)453
Direction/P ositi
dering, sleeve, Excess /
(Land
on
fuse) Loose/M iss
wrong/excess/n
missing/NG 20%
ot cutt
8%
12%
2026
1257
639 622
274
56 23
Cut Crimp ECT FVI Cut Crimp ECT FVI Cut Crimp ECT FVI
Top Defects: April 2009
Circuit APR-09
Insulator too
(crossed/open/
long/Wire
missing/loose/S
Stands
hort)
25%
35%
Tube
(V.T/V.S,Cot,Se
Clip/Clamps/Grt. Taping short /
al,fuse,foam,sol
Direction/P ositi Excess /
dering, sleeve,
on Loose/M iss
fuse)
wrong/excess/n 20%
missing/NG
ot cutt
8%
12%
Counter
measures
for
Internal Defects
Daily Gemba Activity
Daily Report is
discussed.
The Areas with
higher defect rates
are highlighted.
Line leaders are
given the tip for
effective Corrective
Actions.
Daily Gemba Activity
Daily Defects are
discussed with all line
leaders to minimize the
daily defects
Daily Gemba Activity
Clip Pictures
posted to ensure
the Correct clip is
used.
Clip Position/Direction Wrong
Causes Counter Evidence
Measure
Training Provided.
Operator Missed Clips provided in
the Clips (New packets at Final Assembly
Product
in exact quantities.
understanding
problems) Number of Clips in
packet is equal to the
required number of clips
in harness.
Pictures of each Clip
posted on all boards.
Clip requirement along with direction mentioned on all Boards
Taping Missing/Excess/short
• Urethane foam is a
delicate part and can Paper covers applied
easily be damaged on urethane foams
because of
environment or during
handling
Additional Pictures for the Corrective measures.
Additional Pictures for the Corrective measures.
Wrong Insertion
• Location Wise Data Collection for Critical
Assemblies
Root Cause :
Same Color same gage
wires inserted on same
station
Quality Alerts
posted showing
OK and NG
condition of Lock
WRONG CUTTING LENGTH
• Appeared for the first time due to wrong cutting of whole bunch on
KOMAX
PPM = 18
HONDA PPM Target for Year 07-08
Par t Supply A p r' 0 7 ~ M ar' 0 8 A pr-08
100
50
0
0
0
Ac tual - 84 Ki Apr-0
HONDA PPM 08-09 AND NEW TARGET
Par t Supply A pr-09
100
25
0
0
0
Ac tual - 85 Ki Apr-09
Honda Rating for the Month
Customer Complaints – 13 Months Data
(APRIL 2008 – APRIL 2009)
COMPLAINTS
CUSTOMOR MTD YTD
WH CUSTOMER COMPLAINTS (Apr 08- Apr 09)
12
HACPL 1 20
10
IMC 1 10 8
6
SIGMA 0 0
4
HINO 0 0 2
0
PSMC 0 0
Apr- May- Jun- Jul- Aug- Sep- Oct- Nov- Dec-
HACPL Jan- Feb- Mar- Apr-
IMC
DYMCL 0 0 08 08 08 08 08 08 08 08 08 09 09 09 09
TOTAL 0 30
04-08 04-09
DEFECTS
0 2
Customer Complaints & Sigma Level
Customer Defects & Sigma Level (Apr 08 - Apr 09)
10 ∞ 9
8
9 8
8 6.12 6.22 7
7 6
6
Sigma Level = 6.22 5
5 Target Sigma = 6.0
4
4
3 3
2 2
1 1
0 0
Apr-08 May- Jun-08 Jul-08 Aug-08 Sep- Oct-08 Nov-08 Dec- Jan-09 Feb-09 Mar-09 Apr-09
08 08 08
10 228 250
9
8 200
7 131 143 Target PPM = 69
6 150
5 94
4 64 95 18 100
3
51 58
2 21 32 50
1 0 0
0 0
Apr-08 May-08 Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09
Expected Saving:
Saving per Harness : Rs.136/Harness
Monthly Saving (Xli) : Pak Rupees 204,622
Monthly saving (all models): Pak Rupees 409,244