Author : Sandeep Sharma, Rohit Sharma and Kushal Kamboj

A fuel tank cap plays a very important role in the vehicle fuel system. FT Cap act as safety valve mounted on the vehicle fuel tank that provides safety to the biker so it is very important to do the proper function in the vehicle. This work mainly deals with a fuel tank cap and how to fix its lever operational movement. The main parts of Cover Top, Ring body, Cover cap, Actuator, Stator, Dowel, Steel ball, Washer. Fuel Tank Cap for HERO India has the problem of movement jam. This Fuel Tank Cap is a very important part of vehicle being used to close the fuel tank. This rejection is contributing major part in total rejection cost & top ranking in ppm data. This project is basically done to analyze & to get the solution of the causes of movement jam problem in Fuel Tank Cap by using PDCA cycle technique and why-why analysis and some graphical analysis also done. First of all, to reduce the cost and increase the efficiency of the operation, we have identified the problem, collected the Data, done Process study & analyze the problem. Data analysis was done by using the ABC analysis, Pareto graphs & brain storming. Some minor improvements were suggested and implemented there by upgrading the process & Quality requirements.

Keywords: Fuel tank cap, PDCA Cycle, Root cause analysis

Article published in International Journal of Current Engineering and Technology, Vol.7, No.3 (June-2017)