Under the Guidance

of:
Mr. Mandeep Singh
Designation:
Deputy Manager

MAHINDRA &
MAHINDRA SWARAJ
DIVISION
(Farm Equipment Sector)
FINAL PRESENTATION

Department.:
Field Quality
DepartmentWarranty Section

Name: Ashish Sharma

College: SBSSTC, Ferozeper
Branch: Mechanical
Engineering

INTRODUCTION TO MAHINDRA RISE

ITS FOCUS:
power mobility,
drive rural prosperity,
enhance urban lifestyles,
increase business efficiency.
THREE BASIS TENETS:
Accepting no limits,
Thinking alternatively,
Driving positive change in everything.

THINKING GLOBAL IS PART OF MAHINDRAS IDENTITY.

M
A
H
I
N
D
R
A

BACKGROUND
IN 1945:
Mahindra & Mohammed was originally incorporated by the brothers J.C.
Mahindra and K.C. Mahindra and Malik Ghulam Muhammad in Ludhiana,
Punjab to trade steel.
IN 1947:
Malik Ghulam Muhammad left the company and emigrated to Pakistan.
There he became the first finance minister of the new state.
IN 1948:
K.C. Mahindra changed the company's name to Mahindra & Mahindra.
IN 1956:
Listed on the Bombay Stock Exchange.
IN 1982:
Created the Tractor Division and Tech Division ( named Tech Mahindra)
IN 2011:
Launches the new cooperate brand, MAHINDRA RISE.

M
A
H
I
N
D
R
A

GROUPS REPUTATION
Currently, Mahindra & Mahindra is one of the 20 largest companies in India.
In 2011, Mahindra featured on the Forbes Global 2000 list, a listing of the
biggest and most powerful listed companies in the world.
Dun & Bradstreet also ranked Mahindra at No. 1 in the automobile sector in
its list of Indias Top 500 Companies.
In 2010, Mahindra featured in the Credit Suisse Great Brands of Tomorrow.

LEADERSHIP

o
o

o
o
o

Mr. Keshub Mahindra, Chairman Emeritus of Mahindra & Mahindra.

A graduate from Wharton, University of Pennsylvania, USA.
Joined the company in 1947 and became the chairman in 1963.
Mr. Anand Mahindra, Chairman and Managing Director of M&M.
Graduated from Harvard University
MBA from Harvard Business School.
Joined the Mahindra Group in 1981.

M
A
H
I
N
D
R
A

GROUPS BUSINESS

Aerospace
Aftermarket
Agribusiness
Automotive
Components
Construction Equipment
Consulting Services
Defence
Energy

Finance and Insurance

Industrial Equipment
Information Technology
Leisure And Hospitality
Logistics
Real Estate
Retail
Two Wheelers
Farm Equipment

M
A
H
I
N
D
R
A

M&M SWARAJ DIVISION

SWARAJ means freedom from bondage
PTL was the first largest tractor project in India, moreover fully based upon
Indian technology. So, SWARAJ was appropriately chosen as its brand name.

BACKGROUND
IN 1965:
SWARAJ tractor was established.
IN 2007:
PTL was acquired by Mahindra & Mahindra.

GROUPS REPUTATION
Second tractor company in India to have won the prestigious Deming Prize
Award.
Achieved ISO 14001:2004 & OHSAS 18001:2007 certification and TS 16949
certification for Swaraj Automotive Ltd.

M
A
H
I
N
D
R
A

COMPANYS VISION & MISION

VISION
SWARAJ no. 2 brand in India with global
presence

MISSION
3-2-3
In three years double the revenue,
Triple the profit

DIVISIONS OF SWARAJ
1.
2.
3.
4.
5.
6.

Swaraj Tractor Division (STD) Mohali

Swaraj Combine Division (SCD) Chapparcheri
Swaraj Foundry Division (SFD) Mazri
Swaraj Automotive Ltd. Nabha
Swaraj Engine Division (SED) Mohali
Swaraj R&D Unit Mohali

M
A
H
I
N
D
R
A

SWARAJ TRACTOR DIVISION (STD)

Established in 1970
The first to be set among all other divisions.
The first batch of tractor was rolled out on November 14, 1973.
Commercial production started in 1974.
Indias first large-scale project on totally indigenous design and technology.
Presently, around 320 tractors are produced in a day in two shifts in both the
plants.

VARIOUS DEPARTMENTS

Production Department
Finance Department
Marketing Department
Human Resource Department (HRD)
Quality Assurance Department (QAD)

M
A
H
I
N
D
R
A

SUB-DEPARTMENT IN QAD

New Product Development

Manufacturing Quality Department
Supplier Quality Department
Warranty / Field Quality Department

FIELD QUALITY DEPARTMENT

This department studies on field returned components and their statistics and
analyses the failure modes as per their priority level.
It works as a co-ordinator that gives the drive to the concerned department for
taking the action regarding the failure mode and thus assures the quality product
to the costumer.

M
A
H
I
N
D
R
A

PRODUCT LINE OF SWARAJ

SWARAJ
SWARAJ
Tractors
Tractors

722
722
724
724
735
735
744
825
825
834
834
841
843
855
855
939
978

Harvester
Harvester
Combines
Combines

Automotive
Automotive
Casting
Casting

Automotive
Automotive
Components
Components

Light
Light Commercial
Commercial
Trucks
Trucks

Mini
Mini Buses
Buses &
&
Ambulances
Ambulances

Diesel
Diesel
Engines
Engines

M
A
H
I
N
D
R
A

DAILY WORK MANAGEMENT AND LEARNING

Checking of cracking and holding pressure of Relief Valve by using
appropriate apparatus.
Checking of run out of Front and Rear Wheel Rims by using fixture.
Checking of working of Horn, Flasher and Starter Switch.
Checking of working of Hour Metre and Odometer by using RPM Counting
Machine.
Checking of working of Fuel Gauge and Float Assembly by using appropriate
apparatus.
Checking of working of Oil Pressure Switch.
Checking of working of Neutral Safety Switch by using a fixture.
Checking of leakage in Fuel Pipes, Water Separator, Sub Tank and Radiator.
Checking of flatness of Response Valve by using Filler Gauge.
Checking of angle of KPSA (King Pin Stub Axle) by using Bevel Generator.
Assistance in Line and Yard audit in Plant 1.
Preparation for weekly warranty meeting held on Friday of every week.

M
A
H
I
N
D
R
A

PROJECT-I
SUB TANK COOLANT LEAKAGE
I
I.1

PROBLEM - Identification & Definition

Problem Title i.e. Problem Definition:
To reduce the coolant leakage from Sub Tank Assembly.
Current Status: 0.05 RPH (Repair Per Hundred) within 0-2000Hrs.
Target Taken:
Zero Level

M
A
H
I
N
D
R
A

SUB TANK COOLANT LEAKAGE

I.2

History of the Problem:

M atur
e
0.12

Project
Undertak
en

0.10

0.10

0.09

0.08

0.07

0.07

RPH
0.06

Sub Tank Failure Data

Unmature

0.05

0.04
0.04
0.02
0.02

0.05
0.03
0.02

0.00

0.07
0.05

0.05

0.03

0.020.02

0.00

0.03

0.05

0.04

0.02

0.02
0.00

0.00

Production Months

Inference: Problem is persistent.

0.04

0.04
0.02
0.000.00

0.00

0.000.000.000.00

M
A
H
I
N
D
R
A

SUB TANK COOLANT LEAKAGE

II
II.1

OBSERVATION Recognition of Features of the Problem

Observation of the Process:

M
A
H
I
N
D
R
A

SUB TANK COOLANT LEAKAGE

II.2

Vendor Visit- to know the manufacturing process:

Vendor Visit.mp4

M
A
H
I
N
D
R
A

SUB TANK COOLANT LEAKAGE

III

ANALYSIS Discovery of Main Root Causes

M
A
H
I
N
D
R
A

SUB TANK COOLANT LEAKAGE

III.1
Sr.

PHYSICAL INSPECTION of Failed Parts:

PROBABLE CAUSES

TESTING METHOD

OBSERVATIONS

PHOTOS

VALID/NOT VALID

Clearance b/w cap to cap head

Analysis of cap and cap head

Clearance found OK

N/A

Not Valid

diameter

cross section through profile

No.

1.

projector

2.

Tank Head deflashing improper

Visual Examination

Flash at parting line

Valid

3.

Misalignment of tank parts from

Visual Examination

Misalignment from parting line

Valid

Line Audit Done

Filling of coolant is up to the full

parting line

4.

Overfilling of coolant

N/A

Not Valid

N/A

Not Valid

mark
5.

Use of offset cut O-ring in cap

Visual Examination

No such case is reported

6.

Contact of O-ring improper

Visual Examination

Point contact is observed

Valid

M
A
H
I
N
D
R
A

SUB TANK COOLANT LEAKAGE

III.2

WHY-WHY Analysis :

Tank Head deflashing

improper

Misalignment of tank
parts from parting line

Face cutting is not

performed properly

Die parts are not properly

aligned

Manual cutting without

using fixture

Die closure is not

appropriate

III.3

Contact of O-ring is not

proper
Seating Area is in point
or in line contact with
cap face

Root Cause:
Manual cutting without using fixture.
Die closure is not appropriate.
Seating area is in point or line contact with cap face.

M
A
H
I
N
D
R
A

SUB TANK COOLANT LEAKAGE

IV

ACTION - To eliminate each Root Cause

S.No.

Root Causes

1.

Die closure is not

appropriate

Action Implemented

Photos

New M/C has been in action with

(i) constant flow rate of raw material and

Date of Implementation
Oct.13

(ii) hydraulic closure of die

2.

Manual cutting without

using fixture

3.

Seating area is in point

or line contact with cap
face

(iii) No need of cutting by using fixture

because improved product has clean catted
edges itself.

2 Grooves are inserted in the O-ring to

increase the contact area

BEFORE
No Grooves are there

AFTER Improvising of 2
grooves O-ring

Nov13

M
A
H
I
N
D
R
A

SUB TANK COOLANT LEAKAGE

V

CHECK Confirmation of effectiveness of actions

RPH graph After Improvisation

0.12

Unmature

M ature

0.10

Project Undertaken

0.07

0.07
0.05

0.06

0.05

0.04

0.04

0.10

0.09

0.08

RPH

Action Implemented

0.03

0.02

0.02

0.02
0.00

0.03
0.020.02

0.00

0.07
0.05

0.05
0.03

0.05

0.04

0.04

0.04
0.02

0.02
0.00

0.02
0.000.00

0.00

0.01 0.02
0.000.000.00 0.00 0.000.00

0.00

40483 40544 40603 40664 40725 40787 40848 40909 40969 41030 41091 41153 41214 41275 41334 41395 41456 41518 41579
40452 40513 40575 40634 40695 40756 40817 40878 40940 41000 41061 41122 41183 41244 41306 41365 41426 41487 41548
Production Months

VI

CONCLUSION

Structured way of problem solving technique is helpful in fool

proof solutions.
Concept of CFT makes the implementation faster.

M
A
H
I
N
D
R
A

PROJECT-II
STARTER SWITCH NOT WORKING
I
I.1

PROBLEM - Identification & Definition

Problem Title i.e. Problem Definition:
Reduction of Field Failure(R/100) of started switch.
CURRENT LEVEL - 0.11 RPH (Repair per Hundred) within 0-250 Hrs.
TARGET TAKEN- Zero Level.

I.2

Failure modes:

1.

Key sticky in cranking position i.e. key not returning

back to position 1 from position 2.

2.

Key movement free i.e. lock not working

3.

Key not entering in the key hole, key hole damaged

M
A
H
I
N
D
R
A

STARTER SWITCH NOT WORKING

I.3

History of the Problem:

Startar Switch Failure in 0-250 Hrs
0.19
0.170.17

0.20
0.18

0.15

0.16
0.14
0.120.11
RPH

0.12

0.10
0.08

Project Undertaken

Unmature

Mature

0.07

0.11

0.13
0.11

0.09
0.08
0.08
0.07

0.06
0.04

0.15
0.14
0.13

0.13
0.100.11
0.09

0.11
0.09

0.110.11
0.08

0.11
0.09
0.08

0.10
0.09

0.06

0.06

0.04

0.02
0.00
40452
40483
40513
40544
40575
40603
40634
40664
40695
40725
40756
40787
40817
40848
40878
40909
40940
40969
41000
41030
41061
41091
41122
41153
41183
41214
41244
41275
41306
41334
41365
41395
41426
41456
Production Months

Inference: Problem is persistent.

M
A
H
I
N
D
R
A

STARTER SWITCH NOT WORKING

II
II.1

OBSERVATION Recognition of Features of the Problem

Observation of the Process:

M
A
H
I
N
D
R
A

STARTER SWITCH NOT WORKING

III

ANALYSIS Discovery of Main Root Causes

M
A
H
I
N
D
R
A

STARTER SWITCH NOT WORKING

III.1

PHYSICAL INSPECTION of Failed Parts:

10 nos. Failed samples marked F1, F2, F3 ,.F10

S.No.

Parameter

Return spring
not ok, poor
spring action

Aluminium
casting finish
not ok on
D15.5mm

Barrel strips
getting
broken.

Spindle
rotation
sticky

F1

F2

F3

F4

F5

F6

F7

F8

Testing
required

Testing
Method

F10

Observations

Observed poor
spring action in
3 out of 10
failed pieces

REQUIRED

Manual
Testing

Observed poor
surface finish in
6 out of 10
failed pieces

REQUIRED

Visual
Inspection

Observed barrel
broken in 2 out
of 10 pieces.

REQUIRED

Functional
Inspection

Observed
spindle rotation
ok in all pieces

NOT
REQUIRED

Manual
Testing

F9

Inference: Probable causes -Less spring action, Poor casting finish & Lock
barrel broken

M
A
H
I
N
D
R
A

STARTER SWITCH NOT WORKING

III.2

WHY-WHY Analysis:

ROOT CAUSE

Why

Why

Why

Why

Why

Key locks getting

Key not returning

back to neutral
position.

Rotary motion
having restriction
in return.

Lock strip getting

stuck on D
15.5mm seat area.

High points &

uneven surface of
15.5mm seat.

No Machining or
Milling operation
for finishing of this
area

Return spring not ok,

poor spring action

Spring action less

Spring return
force less

Spring wire
diameter less

Barrel strips Broken

Broken due to extra

load

Tempered by
wrong key

Wrong key slot in

if original key
lost

stuck on cranking
position

III.3

Root Causes:

No Machining or Milling operation for finishing of this area

Spring wire diameter less

Wrong key slot in if original key lost

M
A
H
I
N
D
R
A

STARTER SWITCH NOT WORKING

IV
S.NO.

ROOT
CAUSES

Key locks
getting stuck
1
on cranking
position.

Return spring
2 not ok, poor
spring action

Barrel strips
3
Broken

ACTION - To eliminate each Root Cause

COUNTER MEASURES

BEFORE ANS AFTER EFFECTS

IMPLIMENTATION
DATE

Milling operation added on 15.5mm

diameter seat area to remove uneven
surface & highpoints.

October,2013

Return force of Return spring increased

by changing wire diameter from 1.2 mm
to 1.3mm & open end angle changed to
increase return force.

October,2013

Torsion spring end length increased to

ensure complete resting on the seat area

November, 2013

Modified the lock barrel. Narrower entry

point with Z-pattern .Thickness of the
barrel increased by 0.1mm to increase
barrel strength

November,2013

M
A
H
I
N
D
R
A

STARTER SWITCH NOT WORKING

V

CHECK Confirmation of effectiveness of actions

RPH Graph After Improvement

RPH

ACT ION
PTROJECT
AKEN UNDERT AKEN

0.19
0.20
0.17
0.17
0.18
0.15
0.15
0.16
0.14
0.13
0.13
0.13
0.14
0.12
0.11
0.11
0.11
0.11
0.11
0.11 0.11
0.11
0.12
0.10
0.09
0.09
0.09
0.09
0.09
0.10
0.08
0.10
0.08
0.08
0.08
0.07
0.06
0.06
0.08 0.07
0.06
0.06
0.06
0.03
0.04
0.04
0.02
0.01
0.00
40452
40483
40513
40544
40575
40603
40634
40664
40695
40725
40756
40787
40817
40848
40878
40909
40940
40969
41000
41030
41061
41091
41122
41153
41183
41214
41244
41275
41306
41334
41365
41395
41426
41456
41487
41518
41548
41579
Production Months

VI

CONCLUSION

Structured way of problem solving technique is helpful in fool

proof solutions.
Concept of CFT makes the implementation faster.

M
A
H
I
N
D
R
A