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Defects In Molded Housing - For Automotive Industry

PROBLEM:

The plant supplying components for a leading automotive OEM in Europe had complaints due to molding defects

BACKGROUND:

The plant in Hungary making molded components that went into the subassembly for a high-end car in Europe realized that there were manufacturing defects that could not be detected during production and subassembly processes. Field failures were on the increase and this severely impacted credibility of the company.

SOLUTION:

To begin with, day to day data was collected and analyzed using Multi-Vari study options. We had to identify and address high-level focus areas. Also, a measurement system analysis of the online pressure testing equipment was carried out to ensure that testing simulated real life situations. The Multi-Vari study helped us reduce the most probable variables that contributed to the defect. We setup a DOE (Design of Exponents) in order to understand key contributors for the molding issue. The DOE helped us to identify issues in mold as well as the machine set up.

RESULT:

The molding issue was completely eliminated. New test jigs were set up to screen all the parts that were produced previously and only that got sent to the subassembly.

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Pradeep Kumar, Chief Executive

Pradeep Kumar has about three decades of professional experience against his name.  With multi-location and multi-cultural exposure paired with a Master Black Belt in Six Sigma & Lean, Pradeep’s core expertise comes from over a decade of specialization in a large multinational manufacturing company. He is a Certified MBB in Lean and Six Sigma by SBTI, Texas and trained by Mckinsey Consultants as a Lean Practitioner in Rock Hill-USA.

He currently works with large multinational companies, helping them drive Operational Excellence and implement lean strategies. Pradeep also guides senior leadership towards excellence in execution. He has trained candidates in Lean & Six Sigma in India, China, Japan, Thailand, Europe, Middle East, Sri Lanka and the USA; and mentored more than 500 Engineers and Managers in Lean & Six Sigma in India and overseas.  His expertise lies in understanding gaps in current systems, designing more effective processes and mentoring teams to swiftly achieve organizational goals

M.BALAJI, Principal Consultant, Management Systems

Balaji is a Mechanical Engineer with four decades of experience with the last thirteen years in Management consultancy.  His expertise is in Management Systems, with extensive experience in training, auditing and supporting imp mentation of Quality and Environmental Management systems.   He is also a qualified tool designer from NTTF and GTTC.

Balaji keeps abreast of the latest changes in international standards for implementing quality management systems and is a Lead Auditors for ISO 9001, ISO 14001,  ISO 9001, ISO 14001,  ISO 45001, ISO 22163 :2017.  Also auditor for  IATF 16949:2016.  He is a  Lead Assessor : EXIM Bank award for Business Excellence model .  With more than a decade of experience in management consulting, he has conducted 600 man-days of training and 250 man-days of audits; working with more than 35 clients.

ABRAHAM MATHEWS, SENIOR CONSULTANT

Abraham has more than two decades of experience in Quality Management and Operations, including designing quality, environmental and health & safety management systems, managing industrial engineering activities and heading a Plant.  He is an expert auditor of quality systems and in working with teams to implement robust processes that is sustainable.  Having worked in Aerospace and Automotive industry he understands the Industry requirements and is very meticulous in his approach in implementing the required standards.  He is also a trained Lean practitioner and support training and implementing Lean Manufacturing Systems. He also conducts Yellow belt Six Sigma training and supports Green belt training.