Project 2

Here, we can approach the problem in two main parts:

Part 1: 8D Problem-Solving Approach for H-Point Deviation

Step 1: Define the Problem (D1)

• The H-Point (Hip Point) of the seat is not matching the OEM's specified value.
• Issue found in 56 seat sets out of 3250 produced.
• Root cause traced to foam hardness not being as per specifications.

Step 2: Containment Action (D2)

• Stop production of faulty foam parts.
• Mark and isolate defective seats.
• Notify suppliers and production teams.

Step 3: Root Cause Analysis (D3)

Use 5M (Man, Material, Machine, Method, Measurement) analysis:

1. Man – Were workers properly trained for foam molding?
2. Material – Were incorrect foam hardness materials used?
3. Machine – Was the foam molding machine calibrated correctly?
4. Method – Any process deviation in foam curing?
5. Measurement – Were proper ILD (Indentation Load Deflection) tests conducted?

Step 4: Develop and Verify Corrective Actions (D4–D6)

• Perform Pugh Analysis to compare alternative solutions for fixing foam hardness.
• Adjust foam density and chemical mixture.
• Perform hardness revalidation tests.
• Implement additional quality control steps.

Step 5: Prevent Recurrence (D7)

• Update SOP (Standard Operating Procedures) for foam manufacturing.
• Implement regular quality audits.
• Provide training to workers.

Step 6: Recognize Team Efforts (D8)

• Acknowledge and document improvements.
• Ensure long-term monitoring of seat H-Point accuracy.

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Part 2: Track Peel-Out Strength Calculation

We will use static equilibrium and moment calculations based on the given data.

Assumptions:

1. Forces on the mounting points are mainly due to seat weight.
2. The Peel-Out Strength is the maximum force at which the seat track will detach or deform under load.
3. Moment Calculation is done around one of the mounting points.

Formulae Used:

1. Weight Force = F=mgF = mgF=mg
   where m =18 kg, g = 9.81 m/s²
2. Moment due to seat weight around mounting points:
   M = F × d
   where ddd is the perpendicular distance.
3. Shear Force on each mounting point (considering 2-point mounting).

🔹 Hand calculations will be done assuming missing data such as seat track material strength and bolt specifications.