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Application of Quality Tools in Resolving Leak Testing Problem in Automobile Engine Assembly
Case Studies   »  
(May 17, 2020)

The Intake Manifold forms a major part of the engine assembly fitted on a heavy commercial vehicle. It plays a significant role in achieving optimum performance of the engine. Any leakage, if it goes unnoticed at supplier’s and/or at customer’s end, may lead to poor performance of the engine or premature failure of the engine. In this project we focused on the basic parameters of the Leak Testing process and subsequently, horizontal deployment was initiated ensuring rigorous implementation of the basic process control parameters of the involved process. As a result of this, Zero PPM could be sustained. Cost of Poor Quality (COPQ) reduced considerably. Delivery became faster as the rectification time at final inspection got eliminated. Introduction: The component 6 Cylinder Intake Manifold, supplied to national/international Automobile Mfg organizations forms a major part of their engine assembly fitted on a heavy commercial vehicle & directly affects its engine performance. Repeated incidence of leakage in 6 Cylinder Intake Manifold during engine assembly testing at customer end was of great concern. The top management embarked on the project of rejection elimination at customer end. A Cross Functional Team (CFT) was constituted with Managing Director as the mentor and the Business Head as its leader. Team members were drawn from Foundry, Quality Assurance (QA) and Assembly processes. Project commenced on 10th December, 2011 and was completed successfully by 15th January, 2012. DMAIC methodology of Six Sigma was adopted. It started with ‘Problem Definition Phase’.

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