Project: Eliminating Tyre Fouling to Steering Column Cup Concern

This project report details the successful elimination of tyre fouling in the steering column cup of the Alfa Plus vehicle model. The project, undertaken by a Chief Project Developer, addressed customer dissatisfaction and significant financial impacts caused by the issue. The report outlines the project's background, objectives, and the developer's responsibilities, including problem analysis, solution implementation, and cost management. Key steps included identifying the root cause of the tyre fouling, which was determined to be spring stiffness, and implementing corrective measures such as adjusting the spring stiffness. The project followed a structured approach, including defining the problem, forming a team, creating a project plan, analyzing data, implementing solutions, and confirming results. The report also discusses engineering knowledge applied, challenges faced, and tangible benefits achieved, such as cost reduction and improved customer satisfaction. The project concluded with standardized procedures, updated documentation, and training to ensure long-term effectiveness.

CE 2.1 Project Information
Name of the project: To Eliminate Tyre Fouling to Steering Column Cup Concern
Location of the project: Please fill
Project Duration: From 14th May of 2014 to 10th November 2015 (1 year)
Organization: Please fill
Role and Designation during the time: Chief Project Developer
CE 2.2 Project Background
CE 2.2.1 Characteristics of the project
An automotive steering column can be referred to as a device that is intended primarily
for an effective connection of steering wheel to the steering mechanism. There are some of the
major and the most significant functions of steering column, which include energy dissipation
management within frontal collision, providing mounting for the column lock, transmission fear
selector, column shrouds and multi functional switching. This type of steering column is also
effective for offering adjustments to suit driver preferences. This was first project in professional
career. While working with steering column, I got the opportunity to be an important part of this
project for elimination of tyre fouling to the steering column. The main reason for execution of
this project was that, tyre fouling was one of the major issues faced in steering column and it
ended up with customer dissatisfaction, negative effective of sales in Bijapur and Kerala market
areas. I selected the vehicle model of Alfa- Plus for this project and ensured that the project is
completed within deadline. The issue was extremely big; around 1.4 and 1.5 RPT that eventually

affect ted 3 MIS and 12 MIS. Thus, in this project work, I have efficaciously proposed the
solution of tyre fouling to steering column cup effectively after considering all technical and
project specifications or standards.
CE 2.2.2 Objectives developed for the project
I have maintained few of the most significant and major standards during the execution of
this particular project and for the reason that this type of designing or working parameters were
being followed efficiently. Therefore, for completing the project and even providing a perfect
solution to the issue faced for Alfa Plus, I have developed few objectives:
 To suggest a detailed as well as proper solution to the issue faced in the steering column
of Alfa Plus.
 To understand the issue of tyre fouling and evaluate this issue on a priority basis.
 To solve issue for customer dissatisfaction for front tyre fouling with steering column cup
within Alfa plus model.
 To make a proper plan for completion of work and take regular updates.
 To form a project team for providing accurate and efficient work.
 To find solution for dealer replacing the steering column, shock absorber and front coil
spring.
 To attribute data with proper effectiveness and identify the stages, in which this problem
could be detected.
 To check impacts on customer, Mahindra brand and department goal.

Project Supervisor
Chief Project
Developer (Me)
Team MemberTeam Member Team Member
CE 2.2.3 My area of work
Since I have experience in core mechanical engineering project and similar works, I was
appointed as the main project developer here. After providing a proper solution to the respective
tyre fouling to steering column project, I also have to help my respective fellow team members
to understand the subsequent requirements of project as well as the process or working principles
of steering column with significant details. I divided this project into few relevant steps, so that
execution of the work is much easier. With my leadership skills, I was also able to guide my
fellow team members in this project.
CE 2.2.4 Project Group
Figure 1: Team Members Associated with the project
CE 2.2.5 My responsibilities throughout the project
In this particular project of the tyre fouling to steering column cup, I was subsequently
assigned to propose a proper solution to the issue. Since, this was my first in professional career,

I gave extra attention to the minute details of this project work. I noted that EASC or Energy
Absorbing Steering Column is one of the most significant types of steering columns that helps to
reduce the injury of car driver while driving and during accidents. Tyre fouling is one of the
major and the most significant issues that is being faced in the concerned field of steering
column. This particular project was executed since after analysis, it was noted that in the vehicle
model of Alfa Plus, tyre fouling is extremely common and this was becoming a major cause of
customer dissatisfaction. As per my analysis of July 2014, I found out that number of pieces that
were rejected in previous month was 5 and the number of pieces that were 20 (in April to June
2014). Being the project developer, it was my core responsibility to identify the major issues
behind type of tyre fouling and how to deal with such issues. I selected Alfa Plus model as these
were the major reasons of dissatisfaction in Haridwar and Zahirabad. I analyzed the case study
after listing the SSVs, identification of proper tool, collection of data, testing of the hypothesis
and then funneled for the root cause.

Table 1: Cost of Poor Quality of the Project
CE 2.3 Distinctive Activity
CE 2.3.1 Comprehending the Theory of the Project
The major theories of mechanical engineering that I had to consider in this work included
steering column and tyre fouling. The steering column helps in minimization of driver injury
during accidents and it is difficult for assessment of collapse behavior or energy absorber of
steering column. For steering column collapse, I understood that it was impossible for checking
the interference of the surrounding parts. Moreover, it is also impossible to respond or predict t
the collapse test distribution. I had to analyze the previous data from several view points and
hence it was easy for me to understand the current situation and I concluded that the concern
fouling was only present in the Alfa Plus model.
For checking the warranty problem, I checked that internal simulation of failure was to be
done. The failure simulation was done at in house on fresh roll down vehicle with GVW of 975
Kg’s and hence failure was simulated. Regarding quick win implementation, I have used 4 mm
relief that was provided for avoiding fouling on steering column cup. As per the result of
implementation, I observed that fouling was evident even after taking trail with the relief
provided on cup. I even selected the target for this project work.

Figure 2: Graph for selection of Target
CE 2.3.2 Engineering knowledge and skills applied in the project
The major short coming, which I had during the project work was lack of problem
solving skill. During project execution, I did not have the ability to effectively solve every
situational problem that has occurred. However, I became eventually successful to use my core
skills or knowledge of mechanical engineering and steering column and hence solved all of these
problems.
CE 2.3.3 Accomplishment and Task Performed
I had successfully accomplished this task after analysis of the problem faced in Alfa Plus
vehicle model. At first, I listed the SSVs through brainstorming by CFT. The SSVs are listed
below:

Table 2: List down of SSVs
I selected Component Search tool for completing the work. After proper data collection, I
was able to identify the possible cause of tyre fouling in steering column.

Figure 3: Probable Causes of Tyre Fouling
After analysis of all causes, the funneling to next level causes was done.

Figure 3: Funneling to Next Level Causes
Hence, validated cause was spring stiffness to be incremented as benchmarked
with competitor model. Finally, I was able to implement proper solution to the issue of Spring
stiffness to design and finalized in between range of competitor & existing spring.
CE 2.3.4 Identified issues and their solutions
2.3.4.1 Issues
The most important technical difficulty that I have confronted in this work was while
calculating the costs of the project. I had given the responsibility to one of my sub ordinates to
estimate the project costs. However, he was unable to do it perfectly and the costs overshooted
our budget. This became a significant problem for this work and it incurred major delays.
2.3.4.2 Solutions

Regarding issue of budget, I made the budget myself and reduced the costs by reducing
the components required here. The tangible benefits calculated in this case were:
Table 3: Tangible Benefits of Projects
CE 2.3.5 Plan to produce creative and innovative work
I have eventually made a noteworthy strategy to produce an inventive work by applying
skills and knowledge of mechanical knowledge and steering column. These types of creative and
innovative works were required for this project.
CE 2.4 Project Review
CE 2.4.1 Project Overview
The tyre fouling to steering column cup project was being completed properly as well as
the operation was accomplished easily and with efficacy. I had to update the document and train
other people and finally identified the issues and provided proper solutions.

CE 2.4.2 My contribution to work
I had to propose a compact solution to the issue of tyre fouling for the project. I even had
to meet with my entire group so that we are able to clear our doubts regarding project. The major
errors were also eradicated by me.