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WEL COME TO TATA TOYO RADIATOR

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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WEL COME TO TATA TOYO RADIATOR

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  1. Introduction WEL COME TO TATA TOYO RADIATOR Area – 7 Acres Manpower of company – 700 nos Turnover - 420 Cr. (Target 620 Cr. For 2010-2011)

  2. Continued… • Customers

  3. OUR PRODUCTS HEATER CORE – CABIN HEATING Intercooler RADIATOR – ENGINE COOLING ENIGNE COOLING SYSTEM

  4. Our Team Satish Pansare Ajay Bhosale Guide Uday Raut

  5. 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

  6. Data collection Tata Cub radiator Leakage data from Oct-2010 to Dec-2010

  7. Contribution of defects in leakage

  8. Pareto Chart

  9. 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

  10. Details of Tata cub Radiator Assembly Tata cub Radiator assembly Top Tank Pressure cap Clinching area Core Core Support Drain cock Bottom tank

  11. Defect Description Radiator Leakage area edge clinching Defect

  12. 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

  13. Root Cause analysis for defect Clinching Leakage Machine Man Radiator Leakage Clinching tool Tank flatness ? Tank pusher Method Material Tooling

  14. Why-why analysis Why-why analysis for caused 1 – Clinching tool

  15. 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

  16. Continued… Action for model :- Tata cub On Edge clinching tool slot is available Slot is filled with welding

  17. Continued… Action taken for model :- Tata cub Nail open OK clinching After filling of slot

  18. Why-why analysis Why-why analysis for cause 2 – Tank pusher

  19. 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

  20. 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

  21. Continued… Changeover part modified

  22. Why-why analysis Why-why analysis for cause 3 – Tank Flatness

  23. 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

  24. Continued… Plastic tank Toggle Cooling fixture

  25. Tangible benefits Tata Cub radiator Leakage data for 1 Jan to 15 Jan

  26. Tangible benefits

  27. Achievement Rejection reduce from 0.83 to 0.42%

  28. Improved knowledge Confidence improved Stage daring improved Internal customer satisfaction In tangible benefits

  29. After completion of our target 0.83% to 0.43% we select next major defect for Reduction in leakage Future plans

  30. Thank you… Tata Toyo Radiator Ltd. Survey No.235/245, Village-Hinjewadi, Taluka-Mulshi,Dist-Pune-411 027.India Phone No.-+91 20 66524100

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