Project report on concern elimination in Mahindra and Mahindra, Study Guides, Projects, Research of Industrial management

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REPORT ON

CONCERN RESOLUTION

FOR IN-HOUSE MANUFACTURING AT

MAHINDRA AND MAHINDRA

By : A. Vikramaditya

PROJECT

• (^) Achieving 100% rework of A-pillar in XUV 300 at

plot 201 prelaunch of the vehicle and

Implementing a PCA so that the issue will not be

repeated

Current Status: Closed

OBJECTIVES OF THE WORK:-

Achieving Complete Rework of A-Pillars in XUV-300 at plot 201 before the

launch and dispatch of the vehicle to the customer/dealer end.

This project is done with different quality tools like Histograms ,

Root cause analysis and a detailed analogy of how they overcome

such issues from an industrial point of view this includes

identifying a problem to eliminating it in the production process.

Another aspect of this project is to achieve a perfect customer

satisfaction level by delivering a flawless product.

Problem Selection guideline

check whether the Identified issue is significant.

It can be either to solve an existing pain area or for a new gain. It can fall under any

of the following criteria :

• (^) New ideas to meet latent customer needs
• (^) Achieve break through results(>20%) in PQCDSM parameters
• (^) New System / Process
• New training module
• New project tracking system
• (^) An existing quality problem not solvable by traditional tools
• (^) A system for evaluating new project concept
• (^) Breakthroughs required for New Patent

WHY THESE ISSUES WERE

CONSIDERED MAJOR?

A-pillar

• (^) The issue was identified just before the launch of the vehicle ,

due to which it had to be labeled under ICA

• (^) The issue was not only major but we had to rework a total of

1293 vehicles, considering the amount of time and the

organization reputation at stake this had to be eliminated asap

Sash damage

• (^) This has been an ongoing issue and the occurrence

rate was steadily increasing

• (^) Due to this the organization had to call up for an on-

site vendor workshop to resolve this issue, as in this

plant free space is an important aspect, we tried to

eliminate the problem such that there was no need

for an on-site work area

Linkage with Sector

Sector Level Goal

We will have to enhance

Mahindra promise through

it’s crusade of delivering

first time and every thing

right products and

differentiated customer

experience

Nashik Plant

Xuv 300

Elimination of

A- Pillar rework

in Xuv 300

Xuv 300

Reduction of

dents and

damages

OVERVIEW OF XUV -

*note – this is for the diesel variant

REWORK OF A-PILLAR

• (^) The problem of A-Pillar popping out was Observed in plot 201.
• (^) There has been a total of 1293 vehicles already in the plot after the

final rollout before this issue was spotted as a concern The issue was

so serious and a critical concern as a reported number of 40 were to be

sent for test drives three days after the problem was reported which

made it into an ICA.

Flow Chart

Observation of Process (Internal )

Understanding the current situation

Inference from above data analysis—

1.No possibility at M&M to pass vehicle having pillar pop out at CAI as in CAI every

vehicle is checked.

A-Pillar application

A-pillar assy at line vechicle audit at CAI

(customer

acceptance

inspection)

Pillar checking at

CAI

Audit at RFI

( Ready for

inspection)

Vehicle send to

yard

Popping of pillar detected

in Yard

Check point

in plant

IMPORTANCE OF THIS PROJECT

• (^) The new XUV-300 was nearing it’s launch date and this problem was identified 15 days before

hand

• (^) The sheer amount of vehicles that were involved to be reworked were far too many

considering the time on hand

• (^) The launch of this vehicle was seen as a major step in Mahindra as it was all set to succeed

XUV-500 at a lower price point still offering the feel of an SUV

• (^) The approx. amount of money that was involved in replacing the pillars alone was around

3,25,000 inr/-

• (^) The company had a reputation to maintain by avoiding an unsuccessful launch and bad

reviews over the vehicle

• (^) The man power we had at the given time was quite limited as many people were involved in

resolving different concerns of the same vehicle due to the Ramp up in production of the

vehicle, this ramp up gave raise to other unintended problems which were to be solved to

ensure a smooth production of the vehicle.

WHY WAS THIS CONCERN

CRITICAL?

70.78%

14.29%

4.55%

7.79%

1.30%1.30%

Concerns

A Pillar pop out Dent's and damages

Owners manual missing Minor reworks

battery discharge Door auto locked

Highest

severity

When a pie chart was

made at the time of

initial spotting of the

problem it was

observed that this had

the most number of

occurrences , the

percentage was so

huge that it was almost

present in every other

vehicle which was

rolled off into the yard

and also it is to be seen

that the percentage

take on this single

problem was three

times as big as others

PROCESS FLOW OF THE

VEHICLE STORAGE

Roll out

PDI

Activities

Quality

checks

PDI ( pre

dispatch

inspection)

Loading

Transportatio

n to port

Unloading at

port

PDI

Storage at

port

Drive to

vessel side

Process from

left to right

CHA

ML

Plant

Responsibilities Activities

100

140

180

220

260

300

340

380

420

460

500

540

580

620

660

700

Month

Present Level:

Rework of all the new Xuv’s at plot 201

Identify the target - target is a number indicating the level of improvement to be achieved.

Target :^ 100% Elimination by Feb end

TARGET 100%

Elimination

Fishbone analysis

A pillar pop out

Man Machine

Method Material

No being aware of the issue

at the given time period

Melting of 3M tape when exposed to heat

collapse of

mating parts

No step for

application of the

glue onto the

pillar before

mounting it

Weak adhesive

agent