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Anti-corrosion project on PRW Axles, Brakes, Chassis and BUS at FUSO and Improvements in Return Part Management (RPM) area

  • FUSO is one of the Japanese leading manufacturing of trucks and buses in the world and also it is an integral part of Daimler AG. Being a large manufacturer in trucks and buses, Fuso faces some marketing issues due to corrosion issues. Corrosion is one of the major issue to breakdown or damage the performance of the vehicles. To encounter this issue, FUSO initiated new project and called as “Anti-Corrosion Project”. The main mission of this project is to improve the corrosion resistivity or performance of the metal parts. Currently FUSO has almost 70 percent of parts which lies under Grade-III i.e. lesser than the one year corrosion resistivity. In this project, the corrosion issues are collected by different types of audits like from customer as well as from taking two years old vehicle in worst conditions. Listed corrosion issues further investigated for current specification and requested for new proposal from supplier. Then the proposed solution is internally estimate the cost and make negotiation with the supplier. Later it’s forwarded to meeting with top management for approval. In case of higher corrosion specification, parts are taken from production line and tested in material lab which is available in FUSO. At last, the approved proposal is requested to release the drawing change and further the new proposal will be implemented. Entire project it should be coordinate with all different departments and working with teams gives more deep knowledge about the cause of issues. With this project, parallel focused on the shop floor developments in return parts management area. FUSO is also responsible for the after sale services. In other words, FUSO provides warranty for the parts which breakdown within three years. Breakdown parts are directly delivered by the customers through dealers for warranty claim, so these parts called Warranty Part Investigation (WPI) parts. Sometimes customer wants to know the cause of the breakdown even though warranty has expired, in this case company will investigate the cause but they don’t provide the warranty. These kind of parts known as Product Quality Report (PQR) parts. Company has a different shop floor for return parts and these parts are directly received by the company. RPM has four processes i.e. inwarding, pre-analysis, investigation and dispatch or scrap. Usually, company used to get 30-50 parts per day, recently they decided to receive all the breakdown parts. Hence, it results in increasing the delay of inwarding and other processes. To solve this, standard layout and process are constructed. And, one of the main reasons for inward delay is higher documentation which is basically not required. These are converted into automation or digitalize work. Improvements are done using the lean manufacturing project methodology which results in more inward of failure parts and less inventory.

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Metadaten
Author:Annegowda Kalappa Keerthi Prasad
Advisor:Serge Velesco, Sergei Lukin
Document Type:Master's Thesis
Language:English
Year of Completion:2019
Granting Institution:Hochschule Mittweida
Release Date:2020/07/20
GND Keyword:Kraftfahrzeugbau; Korrosion
Note:
Printexemplar Präsenzbestand
Institutes:Sonstige
Dewey Decimal Classification:620.11223 Korrosion, Biofouling
Open Access:Innerhalb der Hochschule
Licence (German):License LogoEs gilt das UrhG