internshipfinalpresentation
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This document summarizes an internship at a Toyota manufacturing plant for quality control. The internship objectives are to develop a defect data reporting and analysis system for manifold lines, assist with preparing for an upcoming TS16949 audit, gain exposure to other departments, take on additional responsibilities, and assist with new product development. Daily tasks include collecting and analyzing scrap data from various production lines, updating metrics and reports, attending scrap reduction meetings, performing process audits, and updating quality documents for the audit. The intern also creates reports on defect analysis, scrap levels, production outputs, and conducts a maintenance project template and Pareto analysis on defects. The internship provided experience with quality tools, standards, and processes as well as
internshipfinalpresentation
- 1. QUALITY CONTROL INTERNSHIP Samarth Patel (847) – 644 – 5128 spate132@hawk.iit.edu Final Year Graduate Student Masters In Industrial Technology & Management - Dec 2014 Bachelors In Mechatronics Engineering
- 2. Internship Objectives Department Objectives • Develop a system for reporting and analysis of internal defect data for Toyota Manifold Lines. • Assist in preparing Bloomingdale plant for upcoming TS16949 audit. My Learning Objectives • Would like to be exposed to other departments of the company. • Want to develop myself by taking additional responsibilities. • Assist in a new initiative undertaken by the company for a new product development.
- 3. DAILY TASK Collecting scrap data from Manifold and Case Lines Updating data at the whiteboard with latest scrap and graphs. Attend daily scrap reduction meeting to assist them with Counter- Measures. Entering data into the spreadsheet. Monthly Production Vs Scrap Reports. Performing Process Audits.
- 4. DAILY TASK Updating quality documents for upcoming TS 16949 audit. Assisting Team Leaders and Supervisor in their daily activities. Assisting Production Mangers in making new graphs. Data collection for new project or for a new material.
- 5. Daily Defect Analysis Case Lines
- 6. MONTHLY SCRAP REPORT CASE LINES
- 7. Daily Defect Analysis Spinner Lines
- 8. MONTHLY SCRAP REPORT SPINNER LINES
- 9. Daily Defect Analysis Manifold Lines
- 10. Monthly Manifold Scrap Report
- 11. SCRAP TRACKER
- 12. Daily Production PPH For SUBARU
- 13. Daily Production PPH For Honda 2GV
- 14. TS CERTIFIED Honda 2GV Inspection Check Sheet
- 17. MAINTENANCE PROJECT • Created a template for unused maintenance sheets. • Real Time Analysis of the data with the help of built in complex Excel Functions. • Flow Chart Analysis of the top 3 defects. • Formulae's used automatically identifies Top Defects and makes the root cause analysis of that defect by taking the total number of defects and dividing it into the individual production lines and further dividing it into individual processes. • Similar to Fishbone Diagram or Ishikawa Diagram.
- 18. PARETO ANALYSIS • It is a statistical technique in decision making used for selection of a limited number of tasks that produce significant overall effect. It uses the 80-20 rule which in terms of quality can be applied as large majority of problems (80%) are produced by a few key causes (20%). • This Pareto Chart enables us to see what 20% of cases are causing 80% of the problem and where efforts should be focused to achieve the greatest improvement. • From this case we can see that we should focus much on Off- Location, Burn Through and Out Of Spec Problem.
- 19. PARETO CHART TABLE # CAUSE - CODE FREQUENCY CUMMULATIVE % 1 OFF-LOCATION – 5 62 28.6 2 BURN THROUGH – 3 61 56.7 3 OUT OF SPEC – 1 42 76.0 4 NO PENETRATION -13 27 88.5 5 OTHER – 14 16 95.9 6 UNDER-CUT – 7 4 97.7 7 BACK BEAD – 10 3 99.1 8 COLD WELD – 6 2 100 9 PITTED WELD – 11 0 100 10 WELD LENGTH – 2 0 100 11 FLASH EXCESSIVE – 4 0 100 12 PIN HOLES – 8 0 100 13 POROSITY – 9 0 100 14 QPR/QIR - 12 0 100
- 20. BREAKDOWN OF TOP 3 DEFECTS OFF - LOCATION
- 21. BREAKDOWN OF TOP 3 DEFECTS BURN -THROUGH
- 22. BREAKDOWN OF TOP 3 DEFECTS OUT OF SPEC
- 23. Skill Development Technical Skills Management Skills - Communication - Teamwork - Interpersonal - Self – Confidence - Networking - Being Proactive - Making A-3 Report - 5 Why Report - Different types of Welding Process - Basics Of Stamping - Understanding on solving QPR - and QIR - Wide use of Excel to create Graphs. - Toyota Engineering Standards - Quality Documents such as Control Plan (MQC), PFMEA ,Process Flow. - Inventory Counting - Sorting. - Introduction to TS 16949.
- 24. Internship Effect • The world of book is completely different than the corporate world. • Practical knowledge is much useful than theoretical knowledge. • Ability to learn something just by watching others. • Never be afraid to speak of what you think. • Use of 5-S in everyday life. • Organizing your work and put a timeline to make your work easier. • Adding this experience to my resume will benefit me after my studies. • Allowed me to use the knowledge learned in class and put it into test.
- 25. My 5 Year Plan Supply Chain And Logistics Fundamentals • EDX • DEC 2014 Design Of Supply Chain Systems • EDX • JUNE 2015 Supply Chain Strategy • EDX • DEC 2015 Certified Quality Engineer • ASQ • DEC 2015 Six Sigma Yellow Belt • ASQ • DEC 2015 Six Sigma Green Belt • ASQ • DEC 2017 Six Sigma Black Belt • ASQ • DEC 2019 Introduction To Programming In Python • Coursera • DEC 2014 Principles Of Computing • Coursera • Class TBA Algorithmic Thinking • Coursera • Class TBA
- 26. THANK YOU