Manufacturing process rejection analysis of heavy duty gear reduction starter motor

Abstract

In manufacturing process the analysis of rejection made by considering various factors such as quality of specification and functional features, productivity issues etc. In this paper an attempt is made to address the failed components and to identify for its causes. Unbalancing of armature is the serious concern for rejection in starter motor when compared to other possible rejection since the material cost and the quality cost incurred for the scarp is very high. In this project we have taken samples of different variants and analyzed by doing tryouts and measuring the unbalancing value each stage and identified the critical process by applying cause and effect diagram, this gives an effective methods to overcome the issues in the process of manufacturing. Various quality tools like Pareto diagram, Interrelationship diagrams have been drawn and various comparison charts were also been drawn and arrived into the final conclusion of what effective measure to be done to reduce the imbalance value which has got a tangible benefit of reducing the rejection in armature. Finally we have designed a core driving machine with proper orientation to the core pack and shaft which plays a major role in reducing the radial runout and facial runout values which directly contributes to the correction of Imbalancing and reducing the process time.