REDUCTION IN WARRANTY ISSUE OF LIFTING PLATE BRAKAGE

Window regulator is a sub assembly used in a automotive car. The window regulator helps in the smooth movement (up and down) of the glass in a car. The window regulator sub assembly of Tata Indica Vista was found to have a large number of rejection causing the highest PPM (Part Per Million) due to defects in the part, high inventory between the process, unbalanced process line and also due to the under utilization of the resources.The project takes on the objective of reduction of Warranty issue of Tata Indica Vista window regulator sub assembly line. The methodology involves studying of each component of the sub assembly and analyzing the variations occurred in the dimensions of each part of sub assembly. Cause and effect diagram and root cause verification were used as the tools to find the cause for the rejections. The problem was with the part known as Lifting plate, the variations with the dimensions of the Radius in wire rope end crimp of upper cable from metal insert & lifting plate. A Radius was designed for the inspection of the incoming parts from the supplier end. After the Radius was implemented this resulted in the achievement of the objective of reduction of the in-house PPM and Warranty issue. The achievement of the above objective enabled the company to raise its sigma value.