VISVESWARAIAH TECHNOLOGICAL UNIVERSITY

BELGAUM, KARNATAKA

Dr. AMBEDKAR INSTITUTE OF TECHNOLOGY

(An Autonomous Institution Affiliated to Visvesvaraya Technological
University, Belgaum)

BANGALORE-560056

2017-2018
DEPARTMENT OF MECHANICAL ENGINEERING
A Report of Internship Training Undertaken at
BOSCH (Bangalore plant)

Under The Guidance of:

Mr Harsha G K
Senior Engineer, Bosch Ltd.
Submitted By:
Mr RANJAN.M 1DA16ME087

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 ACKNOWLEDGEMENT

The attitude bliss and emphasis that accompanies the successful complication of
our task would be incomplete without the expression of appreciation towards
those who have rendered help and guidance throughout my training.

We owe a special thanks to the BOSCH PRIVATE LIMITED for giving me an

opportunity to undergo Internship training at Bangalore Plant.

We would like to take this opportunity to express my sincere gratitude to

Mrs Ambika Kuloor, Manager (MFP Planning) for guiding us throughout
our internship in BOSCH with his valuable inputs and suggestions.

We also very grateful to all the concerned departments, shop managers,

employees and staff members of BOSCH for helping us by sharing their
knowledge and experience in the industry.

We extend our sincere thanks to Dr. B.R. Ravindra, HOD, Dept. of ME,
Dr. AIT Bangalore for granting me the permission to take up this internship.

We would finally like to thank BOSCH PRIVATE LIMITED Bangalore for

giving us the permission to carry out internship at this esteemed organization.

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Contents
i. About Bosch Group ............................................................................5
ii. ABOUT BOSCH INDIA ..................................................................6
iii. Milestones: .......................................................................................7
iv. SIX QUALITY PRINCIPLES OF BOSCH: ...................................8
v. CUSTOMERS/APPLICATION OF BOSCH ‘A’ TYPE FUEL
INJECTION PUMPS ............................................................................9
1. FUEL INJECTION PUMP..............................................................10
1.1 What is fuel injection pump .......................................................10
1.2 Types of Fuel Injection Pump ....................................................11
1.3 Assembly process of Pump ........................................................13
1.4 Tightness .....................................................................................14
1.5 Phasing ........................................................................................14
1.6 Calibration ..................................................................................15
1.7 Over Checking ............................................................................15
1.8 Pre-Packing:................................................................................15
1.9 Box Packing ................................................................................16
2 Governor ...........................................................................................17
2.1 Introduction.................................................................................17
2.2 Types of Governor ......................................................................17
2.3 Centrifugal/ Mechanical Governor .............................................18
2.4 Types of governors used in in-inline pumps ..............................18
2.5 Type RSV ...................................................................................19
2.5.1 Parts used in the RSV Flyweights ...........................................19
2.5.2 Process flow diagram of Assembly Line of RSV Flyweight ..20
2.6 Type RQV ...................................................................................22
2.6.1 Types of RQV Flyweights .......................................................22
2.6.2 Parts used in RQV Flyweights ................................................23

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 2.6.2 Process flow diagram of Assembly Line of RQV Flyweights 23
3. Centreless Grinding .........................................................................26
3.1 Introduction.................................................................................26
3.2Types ............................................................................................27
3.2.1 through Feed ............................................................................27
3.2.2 End – Feed ...............................................................................28
3.2.3 In – Feed ..................................................................................29
4.1 Quality Principles for the Value Stream .......................................30
4.2 Terms and Abbreviations ..............................................................38

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i. About Bosch Group
The Bosch Group is one of the world’s biggest private industrial
corporations and world’s largest supplier of automobile components, and has
business relationships with virtually every automobile company in the world.
Headquartered in Stuttgart, Germany, the Bosch Group has some 238,500
employees worldwide, and generated annual sales revenue of 47.3 billion Euros
in 2010. There are about 300 subsidiary and regional companies in over 60
countries around the world.
This worldwide development, manufacturing and sales network is the
foundation for growth. Each year Bosch spends more than 3.5 billion Euros for
research and development, and applies for 3,800 patents worldwide, with all its
products and services, Bosch enhances the quality of life by providing solutions
which are both innovative and beneficial.
The company was set up in Stuttgart in 1886 by Robert Bosch (1861-
1942) as “workshop for precision mechanics and electrical engineering”. The
special ownership structure of Robert Bosch guarantees the entrepreneurial
freedom of the Bosch group making it possible for the company to plan over the
long term and to undertake significant upfront investments in the safeguarding
of its future ninety two percent of the share capital of Robert Bosch stiftung, a
charitable foundations.
The majority of voting rights are held by Robert Bosch industrietreuhand
KG, and industrial trust, the entrepreneurial ownership functions are carried out
by the trust, the remaining shares are held by the Bosch family and by Robert
Bosch Gmbh.
The Bosch slogan “invented for life” is part of its long tradition, though
which it communicates the group’s core competencies and vision that include
technological leadership, modernity, the dynamics, and quality and customer
satisfaction.
From the very beginning; the company’s history has been characterised
by innovative drive and social commitment. Bosch is a truly worldwide
company. The Research Technology Centre is located in Palo Alto, CA near
Stanford University. There are also two corporate sites in Brazil and Ten in
Mexico where a central purchasing office for all divisions of Bosch is located,
in North America, Bosch employs about 24,750 people in 80 locations.

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 ii. ABOUT BOSCH INDIA
India, Bosch is a leading supplier of technology and services, and has a
strong presence in the country at numerous locations in diverse industry
segments. Bosch set up its manufacturing operations in 1953, and has grown
over the years to 14 manufacturing sites and 3 development centres. Bosch
employs about 22500 associates in India, and in business year 2010 achieved
total consolidated revenue of over 6630 crores. Founded in 1951, Bosch Limited
is India’s largest auto component manufacturer and also one of the largest Indo
– German companies in India. The company generated net sales of Rs. 6630
crores in 2010. The Bosch Group holds 71.18% stake in Bosch Limited.

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iii. Milestones:
 1951- Establishment of the organisation.
 1953- Construction of the first factory building at Bangalore.
 1954- Manufacture of the spark plugs, single cylinder diesel fuel pumps
and nozzle-holders.
 1955- Manufacture of elements and delivery valves.
 1956- Manufacture of multi-cylinder diesel fuel injection pumps.
 1981- Manufacture of special purpose tools and machines.
 1986- Manufacture of VE distributor pumps.
 1989- Manufacture of hydraulic products.
 1991- MICO becomes the BOSCH global development center for single
cylinder diesel fuel injection pumps.
 1992- Marketing of automotive accessories.
 1993- Manufacture of Bosch electric power tools.
 1994- Manufacture of packaging machines.
 1995- MICO now becomes the BOSCH global development center for a
range of multi – cylinder diesel fuel injection pumps.
 1996- BLAUPUNKT car audio systems launched.
 1997- QS 9000 certification for all manufacturing plants
 1998- 20millionth single – cylinder pump produced.
 1999-Jaipur plant inaugurated. Manufacture of BLAUPUNKT car
systems in INDIA.
 2000- MICO Application Center (MAC) inaugurated.
 2001- Launch of Terrs-25 packaging machine.
 2002- Manufacture of 25 millionth single-cylinder pump.
 2003- Production of 10 millionth Inline-A pump.
 2004- Bosch announces an investment of Rs.1, 000 crores in India over
the next 4 years.
 2005- Bosch received the Deutsche Zukunftspresis (German Future Prize)
 2006- Bosch acquired Telex Communications and Electro-Voice.
 2009- Bosch invested about 3.6 billion Euros in development and
research.
 2012- Bosch purchased SPX Service Solutions.
 2015- Bosch purchases Seeo, Inc., a start-up working on solid li- battery.
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iv. SIX QUALITY PRINCIPLES OF BOSCH:
1. Our goal is to fully our customers through the quality of our products and
services.

2. Quality and improvement, is every associate’s responsibility and ultimate

goal from the board of directors to apprentices.

3. Our directives, processes, system and goals are based on requirements

from the international standards customers’ expectations, our knowledge
and experience.
Knowledge of compliance with these directives and processes is the
foundation of our quality.

4. Quality means doing things right in the beginning, thus preventing

failures in the end. Continuous improvement of the quality of process
lowers the cost and increases productivity.

5. Avoiding failures is more important than eliminating defects. We

systematically apply methods and tools for preventive quality assurance,
learn from mistakes and eliminate their root causes without delay.

6. Our suppliers contribute substantially to the quality of our products and

services. Therefore our suppliers must live up to the same high quality
standards we have adopted.

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v. CUSTOMERS/APPLICATION OF BOSCH ‘A’
TYPE FUEL INJECTION PUMPS

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1. FUEL INJECTION PUMP

1.1 What is fuel injection pump

An Injection Pump is the device that pumps fuel into the cylinder of a
diesel engine. Traditionally, the pump is driven indirectly from the crankshaft
by gears, chains or a toothed belt (often the timing belt) that also drives the
camshaft. It rotates at half crankshaft speed in a conventional four-stroke
engine. Its timing is such that the fuel is injected only very slightly before top
dead centre of that cylinder’s compression stroke. It is also common for the
pump belt on gasoline engines to be driven from the camshaft. In some systems
injection pressures can be as high as 200 Mpa.

Fig. Example of inline pump

In 1927 Robert Bosch produced the first practical diesel pump. This design
enabled the newly developed diesel engine to become a viable engine for many
applications. The method of fuel metering on this initial pump was port and helix,
(high pressure metering). This method of metering was still being used on most
modern injection pumps into 1990’s.

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 Bosch has licensed many companies to build these pumps but they all
retain the basic Bosch design principles. Bosch has designed pumps are used on
many manufacturers’ engines. One of the larger pumps in the Bosch line, the PE/S
series has many heavy-duty features, making it suitable for high-output engines.
These pumps have been used on Mack, Navistar and Cummins and countless
others throughout the world. Larger camshafts, plungers, and non-adjustable
roller tappets enable this pump to be used with nozzle opening pressures of 1,350
Bar, (10,000 to 20,000 psi). The hydro-mechanical versions of these pumps had
many add on features and controls such as a fuel lift pump, smoke limiter,
(aneroid), injection advance unit, and several different governors. The P size
pump is generally used on engines having more than 200 hp.

1.2 Types of Fuel Injection Pump

Types of Fuel Injection

Pump

2.Individual 4. Unit
3.Common Injection
1. Inline Pump control
Rail Pump Pump
Pump

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 Fig. Inline Pump Fig. Individual Control Pump

Fig. Common Rail Pump Fig. Unit Injection Pump

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1.3 Assembly process of Pump

Bearing cover
DV holder sub Bearing tightening
pressure pressing Box Packing
assembly station
m/c

Delivery valve
Cam play over
holder autoscrewing Cam play setting Pre Packing
checking
station

Bearing flange and

Gallery tightness Coupling/ Base cup
bearing cover Over Checking
checking assembly
assembly

Assembly of gear
ring to control rod Governor cover to
Cam IR pressing Callibration
and asby of upper FIP assembly
spring plate

Gasket fixing on G.H

Roller tappet
and G.H to Pump Tightness Phasing
assembly
pressing

Abbreviations:
 DV: Delivery Valve
 G.H: Governor Housing
 FIP: Fuel Injection Pump

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1.4 Tightness

The final assembly is checked for the various leakages through a test
called tightness testing. The pump is placed on the test bench with two pressure
pipes connected to the pump housing and governor housing and it is immersed
in the test oil. The two pressure lines are high pressure lines pipes and low
pressure pipes. The high pressure pipe line is connected to the pump housing
and the low pressure pipe line is connected to the governor housing. The high
pressure applied to the pump housing is about 4.0 to 4.5 bar and low pressure
applied to the governor housing is 1.0 to 1.5 bar. Air leakages from joints like
governor cover to governor housing joint, governor housing to pump joint,
delivery valve holder assembly, base cup assembly or any casting defects like
blow holes is checked. Once it passes the tightness it is punched and sent for
phasing.

1.5 Phasing

The essential functions of the injection pump when fitted to the engine
are to ensure that an accurately metered quantity of fuel shall be injected into
each cylinder at appropriate times and at a pre-determined rate. Therefore it is
very essential that the fuel injection pump commensurate with all the above said
requirements.
The start of injection point is the first for which adjustment is made for
the FIP and thus it should be such that it matches the timing of the engine and
also it takes care of the injection lag (angle of rotation of engine from start to of
injection to ignition). The process of setting start of ignition on FIP is called as
phasing. Pre stroke is set before phasing. Pre stroke is the movement of plunger
from the bottom dead centre to the point where it just covers the spill port. It is
performed only on the comparator bench and can be adjusted by shimming the
pump barrels or the roller tappets. The most important criteria to keep in mind
during phasing is the firing order of the engine. Once the pump is good in
phasing, it is punched and sent for calibration.

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1.6 Calibration

Calibration is the process in which the fuel injection is set:

 To deliver the right quantity of fuel at the right time as required by a
particular type of engine over its entire operating range.
 It helps in achieving the desired performance of an engine in terms of
power, torque, specific fuel consumption and emissions.
This process is carried out on a KFMG-T computerized bench. KFMG
(German: Kontrolle Foerder Merngen Gerate / Continuous Flow Measuring
Range) abbreviation for Fuel Delivery Measuring Equipment. “T” indicates that
the equipment is temperature compensated which allows precise fuel setting in
spite of minimal variation in oil temperatures.

1.7 Over Checking

Once the pump is calibrated, it is over checked to see if the calibration and
phasing has been done within the specification, Phasing over checking followed
by calibration over checking is carried out ensuring the pump is performing as
required. After over checking the pump is sent for pre-packing.

1.8 Pre-Packing:

In pre packing the pump is assembled with protective caps and certain sealing
components that protect the pump from damage during transportation and also
from being tampered with. The following steps are followed while pre packing:
Step1: Torque checking and torque punch.
Step2: Flushing station.
Step3: Governor housing screw plug assembly and lead sealing.
Step4: Removing coupling.
Step5; Inspection cover with gasket assembly.
Step6: Feed pump with gasket assembly.
Step7: Bearing cover O- rings assembled.

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Step8: Protective caps for delivery valve holder.
Step9: Tightness checking station.
Step10: Over flow valve assembly.
Step11: Protective cap for fuel inlet port.
Step12: Applying grease on camshaft and assembly of nut and washer or
protective cap.
Step13: Black sealing caps assembled where ever required.
Step14: Applying yellow lacquer to selected points.
Step15: Send to Box Packing.

1.9 Box Packing

After being Pre-Packing the assembled sent for box packing. In box packing the
pumps are placed inside cardboard boxes and covered. Support is provided to
avoid movement of pumps during transportation. After it is box packed, it is
sent to logistics to be dispatched to the customer.

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2 Governor
2.1 Introduction
Governor is a type of mechanical device which is generally used to determine
and regulate the speed of the engine to the desired level. It is a particular
feedback system used where is the need to control variation of load present in
the system. The main purpose of the governor is to control the flow of fuel into
the engine to maintain a constant speed hence sometimes it is known as speed
limiter. When the load of an engine increases the speed of engine decreases and
vice versa when the load on engine decreases speed of engine increases. This is
where governors play an important role to increase or reduce the fuel flow to
engine according to the requirements.

2.2 Types of Governor

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2.3 Centrifugal/ Mechanical Governor

Mechanical governors used with in-line fuel injection pumps are centrifugal
governors. This type of governor is linked to the accelerator pedal by means of
a rod linkage and an adjusting lever. On its output side, it operates the pump’s
control rod. Depending on the type of use, different control characteristics are
required of the governor.

2.4 Types of governors used in in-inline pumps

The governors used in in-line pumps are given below:

1. Maximum speed governors (Type RQ) – It limits the engine maximum
speed.
2. Minimum/Maximum speed governors (Type RQ and RQU) – It also
controls the idle speed in addition to limiting the maximum speed. They do not
control the intermediate speed. The injected quantity in that range is controlled
by means of accelerator pedal. This type of governors is primarily used in motor
vehicles.
3. Variable speed governors (Type RQV, RQUV, RQVK, RSV and RSUV)
– It not only limits the minimum speeds but also control the intermediate speed
range.
4. Combination Governors – These are the combination of
minimum/maximum governor and variable speed governor.
5. Generator Engine Governor – These are specially used for generator
engines for obtaining desired end governing characteristics (lower speed).
The Bosch centrifugal mechanical governor is mounted on the fuel injection
pump. The pump’s control rack is connected by a rod linkage to the governor.
The control lever on the governor housing forms the link to the accelerator
pedal.

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2.5 Type RSV

The centrifugal force acts via a lever system on the governor spring that is
external to the two flyweights. The two flyweights then act via the sliding bolt
on the tensioning lever to which the governor spring is attached and acting in
the opposite direction.
On the Type RSV (German: Regler Schwenkfeder Verstellbar) governor
(variable speed governor), the driver sets the desired engine speed by tensioning
the governor spring by means of the control lever. On the Type RS/RSF
governor (minimum/maximum speed governor) the governor spring setting for
the high idle speed is fixed and cannot be altered by means of the accelerator
pedal. The governor springs in the movements are chosen so that the spring
force and the centrifugal force are in equilibrium at the desired speed. When
that speed is exceeded, the greater centrifugal force of the weights moves the
control rack by means of a lever system and reduces the pump’s delivery
quantity.

2.5.1 Parts used in the RSV Flyweights

The common parts used in the assembly of RSV Flyweights are:

 Link
 Flyweight
 Sliding Piece
 Straight Pin
 Retaining Pin

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2.5.2 Process flow diagram of Assembly Line of RSV Flyweight

loose pin WST

Id od slider and slider final
honing height pin inspection
turning grinding pin pressing
checking

Fig. Outer Dia Grinding Machine Fig. Honing Machine

Fig. Inner Dia Turning Machine

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Fig. RSV Type Variable speed governor

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2.6 Type RQV

In this Type RQV (German: Regler Querfeder Verstellbar) governor, the

governor springs are fitted inside the flyweights. However, the flyweights move
continuously outwards as engine speed increases within the specified control
range. Every control lever position corresponds to a specific speed at which
speed regulation breakaway begins. The movement of the control lever is
transmitted via the two-piece linkage lever and the guide block to the variable
fulcrum lever and hence to the control rack. The pivot of the variable fulcrum
lever is movable along the sliding block guide: it also runs in a plate cam fixed
to the governor housing so that the transmission ratio of the variable fulcrum
lever also changes. The sliding bolt, which forms the link between the flyweight
speed sensing element and the variable fulcrum lever, is sprung against pressure
and tension (drag spring).

2.6.1 Types of RQV Flyweights

RQV Flyweight is divided into two types:

 RQV – PRG: Where in this flyweight spring is used during the assembly.
 RQV – YPRG: Where in this flyweight spring is not used during the
assembly.

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2.6.2 Parts used in RQV Flyweights
The common parts used in the assembly of RQV Flyweights:
 Flyweight Assembly
 Spring Seat
 Compression Spring
 Round Nut
 Shim
 Spring Disc
 Universal Joint
 WST Pin
 Angle Lever
 Retaining Pin
 Driver
 Rubber Buffer
 Rundmutter
 Flyweight
 Capsule

2.6.2 Process flow diagram of Assembly Line of RQV

Flyweights

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 Incoming Parts

Caulking Process

NO NO Inspection
Rework Gauging
YES
YES

Hinge Pin Pressing

NO NO
Scrap Rework
Inspection
Gauging
YES

Spring Seat Selection

Spring Assembly

Stamping

NO NO
Rework Axial Play

YES
YES

QMM Audit

Rubber Buffer Assembly

Calibration and Marketing

Supermarket

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Fig. Type RQV variable speed governor

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3. Centreless Grinding

3.1 Introduction

Centreless grinding
In centreless grinding, the work piece is held between two grinding wheels,
rotating in the same direction at different speeds, and a work holding platforms.
One wheel, known as the grinding wheel, is on a fixed axis and rotates such that
the force applied to the work piece is directed downward, against the work
holding platform. This wheel usually performs the grinding action by having a
higher linear speed than the work piece at the point of contact. The other wheel,
known as the regulating wheel, is movable. This wheel is positioned to apply
lateral pressure to the work piece, and usually has either a very rough or rubber-
bonded abrasive to trap the work piece.

Fig. Centreless Grinding

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3.2Types

There are three forms of centreless grinding, differentiated primarily by the

method used to feed the work piece through the machine:
 Through Feed
 End – Feed
 In – Feed

3.2.1 through Feed

In through-feed centreless grinding, the work piece is fed through the grinding
wheels completely, entering on one side and exiting on the opposite. The
regulating wheel in through-feed grinding is canted away from the plane of the
grinding wheel in such a way as to provide a lateral force component, feeding
the work piece through between the two wheels. Through-feed grinding can be
very efficient because it does not require a separate feed mechanism; however,
it can only be used for parts with a simple cylindrical shape.

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3.2.2 End – Feed

In end-feed centreless grinding, the work piece is fed axially into the machine
on one side and comes to rest against an end stop; the grinding operation is
performed, and then the work piece is fed in the opposite direction to exit the
machine. End-feed grinding is best for tapered work pieces.

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3.2.3 In – Feed

In-feed centreless grinding is used to grind work pieces with relatively complex
shapes, such as an hourglass shape. Before the process begins, the work piece is
loaded manually into the grinding machine and the regulating wheel is moved
into place. The complexity of the part shapes and grinding wheel shapes
required to grind them accurately prevent the work piece from being fed axially
through the machine

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4.1 Quality Principles for the Value Stream
Principle1: A Stop sign process with all of the 8D elements is displayed on the
shop floor.
A standard review process involving the production/logistics management and
quality management takes place.
The decision to end the STOP sign process is taken by production/logistics
management after a review of the measures’ effectiveness.
It is necessary to ensure that customer complaints are communicated quickly
over the entire supply chain from supplier to customer.

Principle 2: Andon Cord

In the event of deviations in quality or if control limits are exceeded in the value
stream (source, make, deliver), the employee needs to stop the process or
escalate.

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There is a systematics (e.g. Andon cord, blocking/escalation process, reaction
plan) in place that allows the operator, if he notices deviations, to choose to
prevent the passing-on / further processing of parts (by stopping/blocking) and
to escalate immediately.
Deviations can occur if control limits are exceeded, and also based on
subjective observations (for example, the power screwdriver is not running
smoothly, material has been funnelled into the incorrect chute, or the associate
is not working to the standards set, label badly readable or incomplete).
After stopping the system there needs to be a well-defined process governing
the restarting and release of the system by shop floor management.

Principle 3: Instructions
Safety, health, production, and inspection instructions are compiled with 5S
standards are put in place and observed.

The work, production and inspection instructions are clearly visible at every
work place. A consistent set of symbols is available. If appropriate, the right/left
hand movement becomes evident from the instruction. The failure modes from

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the FMEA and special characteristics from the control plan are taken into
account. Detailed photos support the process.
There is a feedback loop in place that ensures the consistency of the control
plan, FMEA, and directions. Health and safety instructions are carried out
according to the plan. Participation is compulsory and will be documented.
All deviations regarding safety, work, production and inspection instructions or
safety and health briefings shall be resolved using the 9D method.

Principle 4: Process Parameters

All process parameters (e.g. press-in force, maximum storage time) that affect
product quality are clearly defined and systematically checked on basis of the
control plan. All required inspection criteria are implemented according to
specification.
Process validations are performed to determine whether target values/tolerances
of the defined parameters have been observed. Deviations are systematically
recorded and eliminated permanently.

Principle 5: Measurement/Test Equipment

The type of measuring and test equipment (e.g. gages, scanners) incl. auxiliary
means and its uses is defined for all processes in the control plans.
All measuring and test equipment is calibrated and only utilized within the
permissible inspection interval.
The inspection status of the measuring and test equipment is recognizable at its
place of usage (e.g. marked by inspection certificate sticker, tag).

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In case of suspected malfunctions/damages this has to be notified.

Principle 6: Check the Checker

The suitability of processes used to prevent or detect errors (e.g. camera-
monitored processes, sensor-based measurements, inspection processes,
scanning of labels) needs to be checked according to a predefined standard.
Possible errors, such as loading the incorrect camera software/testing program
or incorrect MAE software versions/updates, entry of wrong inspection
parameters, or improper sensor calibration, need to be prevented by carrying out
the inspection. These inspection processes, need to be evaluated using
appropriate methods.
Check-the-Checker-parts are included in the control of inspection measurement
and test equipment.
Generally speaking, mistake-proofing is always preferable to error detection
(e.g. Poka Yoke).

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Principle 7: Total Productive Maintenance
The four-pillar TPM model, particularly the autonomous and preventative
maintenance, is instituted at every machine, device, and facility. This contains
both the roles and responsibilities for production and the supporting areas.
Systematic damage and dirt built-up on machinery and device components (e.g.
work piece carriers, storage facilities, stackers) need to be consistently analysed,
recognised, and remedied.
The restart after maintenance (see principle 9) has to consider potential
influences on product quality.

Principle 8: Tools
Wear-prone tools with influence on product quality have been recorded and are
controlled.
A warning system promptly displays when tools need to be replaced or
serviced.
Each tool needs to be inspected when installed, removed or disassembled to
check for recognizable abnormalities. In case of deviations, it is necessary to
follow measures to ensure product quality is maintained.

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Principle 9: Restart
Each disruption to the continuous production process presents a potential risk to
quality. A predefined standard for post-restart is therefore necessary. This
should detail how to deal with products in the process after a disruption.
All devices have been inspected according to a defined standard for quality risks
in connections with disruptions. The standard also includes the analysis of
critical wear parts.
Following longer disruptions (e.g. station upgrade, control software update), it
is necessary to newly release the process.
Set-up processes, need to be evaluated using appropriate methods (e.g. FMEA).\

Principle 10: Labelling

In the entire value stream products must always have a clear status. Therefore, a
consistent identified/labelling concept at the production site and adherence to
the following rules are necessary.
Within the production flow:
 Filled boxes must always be labelled.
Outside the production flow:
White card with a red diagonal stripe: Product blocked:
Green card: Product after additional test back in production flow and in good
condition.
Yellow card: Product for rework:
White card: Product in good condition.
 Rejected parts in the red box.
 Red boxes must be secured against unintended access.

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  Containers for rejects must be emptied in line with standards and the
parts must be analysed.
 Only parts with the same status in the same container.
 No good parts in the red box.
 A blocking process for production and logistics is defined.
 Products are protected against environmental influences in line with
regulations.

Principle 11; Rework/Scrap

Basic rule: inspection or processing of a part that, contrary to the control plan, is
removed from the standard process, is rework.
If rework is unavoidable it takes place on an approved device and is limited in
time or quality. A concession is necessary.
A rework process that is permanently required must be transferred to a standard
process.
Sorting inspections require a
 Risk assessment,
 Description of the workplace,
 Work/inspection instruction.
They are approved by the responsible for production and the responsible for
quality.
Scrap must be disposed of in line with the standard and unauthorized further use
of these products must be prevented.

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Principle 12: Dropped Parts
Each individual employee must adhere to this standard regardless of what part
of the organization he/she belongs to or his/her position within the company.
In case of repeated occurrence the shop floor management must be notified by
the employee. Repeat events are analysed regarding systematic causes and
improvement measure are implemented.
Nonconforming products or products that cannot be classified must be scrapped
according to procedure.

Principle 13: Correct Product

Only the correct product may be available to the associate at the time of
assembly.
All other variants or versions that are stored at the assembly station/workplace
must not be accessible to the employee.
If several variants need to be available, an inspection takes place after the
handling operation.

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Principle 14: Remaining Items
Remaining quantities must be clearly labelled. (E.g. white card with part
number, number of units, date, name, remaining quantity in the common field)
and stored securely.
The “First In, First Out” principle must be observed.
Maximum storage times must not be exceeded.
Close attention must be paid to ensure tidiness and cleanliness as the goods
have yet to be placed in the final packing.
The quality of remaining items must be taken into consideration with regard to
engineering change requests.

4.2 Terms and Abbreviations

5S: Approach for improvement of order and cleanliness at the workplace
described by 5 Japanese words all beginning with S.
8D: Method for structured problem solving in 8 steps.
Andon Cord: Term derived from Japanese for a system (e.g. rip cord, switch,
systematics) enabling an employee to stop a device.
Audit: Systematic and independent investigation of the actual state e.g. of a
quality management system, production process or product in comparison to the
requirements.

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FMEA (Failure Mode and Effects Analysis): Analytical method to identity
failure modes of systems, products or processes and to avoid them by
appropriate measure.
IPN: International Production Network
ISO (International Organization for Standardization): Worldwide union of
national standardization institutes for the development of international
standards.
ISO/TS 16949: Summarizing technical specifications of the worldwide existing
requirements of the automotive industry for management systems, developed by
the ISO.
MAE: Machinery and Equipment.
Poka Yoke (from Japanese): Method to avoid human mistakes, resulting
defects and passing on of nonconforming parts.
RFID (radio-frequency identification): transmitter-receiver system for contact-
free identification of objects using electromagnetic waves.
TPM: Total Productive Maintenance.
VDA: German Association of the Automotive Industry.

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