csb problems june 2013 ( 1-15 ) creative

7/30/2019 Csb Problems June 2013 ( 1-15 ) Creative

1/67

Actual Rew

1 04.07.2011 5123249 Wear Liner Marks on ID Serview Salavged 0

2 04.07.2011 5123241Beam for lifting

slingLight Step observed Technomech Salavged 0

3 04.07.2011 5123261 Fibre glass guard Scratches found during assembly OmkarRework by

Supplier15

5 11.07.2011 5123305 61242802-04 Bracket, FrameBracket, frame --automation part fitment

problemMhalsakant Replaced 0

6 11.07.2011 5123305 61242800-01

Torque arm

bracket, Al

control

Load cell bracket fitment problem Mhalsakant ALIL 0

7 12.07.2011 5123370 61239760-80 Frame Leakage Srujan ALIL 90

8 12.07.2011 5111416 61240424-01Bracket

MachinedFitment problem Mhalsakant ALIL 0

9 13.07.2011 5123302 61232116-01 v-Belt pulley Fitment problem with hub Mhalsakant supplier 10

10 13.07.2011 2.5 Plannet wheel Dents Hero

11 13.07.2011 5123371 61239760-82 Frame 200Main drive pulley & small end hub pulley

alignment problemSrujan ALIL 60

12 13.07.2011 890008 61231946-89 Frame 360 Bowl fitment problem Creative supplier 480

13 15.07.11 5111416 61240289-80 Frame 280 Cover switch holes missmatched. CreativeR/w done in

hold time10

14 15.07.2011 5123325 61242375-81 Frame, VFD

Electrical bracket fitment problem with

frame--Large amount of gap obs betn

Coupling & sensor.

Srujan ALIL 0

15 15.07.2011 5123282 61211803-87-01 Collecting vesselVessel fitment problem with frame--one

hole mismatchedAlok ALIL 15

16 15.07.2011 890008 61241947-43 Top part Top part leakage problem. Dynaxcel ALIL 180

17 15.07.2011 5123293 61240292-01 Motor plate back drive alignment problem Technomech ALIL 180

16 16.07.2011 5123282 61211803-87-01 Collecting vessel vessel fitment problem with the frame Alok ALIL 180

C

Sr.

No.Date M/C No. Part No. Part Name Problem description

Supplier's

Name

R/W done

by


2/67

18 18.07.11 5123309 61242138-82 Top part Nozzle fitment problem with cover Dynaxcel ALIL 0

19 18.07.11 5123275 61241942-83 Frame 360 Backdrive plate fitment problem Bestall ALIL 6

20 20.07.11 5123310 61241942-58 Frame 361 funnel fitment problem with frame Bestall ALIL 1

21 25.07.11 5123283 61211803-87-01 Collecting vessel Top part touches to bowl. Alok supplier 1

22 26.07.11 5111416 61240289-80 Frame 280Dome shape shifted ( Gap uneven ) wrt

radius of top partSrujan ALIL 2

23 26.07.11 5123307 Sensor bracket & fitment problem

24 29.07.11 5123308 61240381-86Centraflex

couplingThreads were damaged. Vulkan ALIL 0

25 29.07.11 5123411 61239783-82 Top Part 280 Top part damaged Srujan ALIL 60

26 29.07.11 5123327 61232744-80 Bracket, Painted uneven casting surface Arni-Mech ALIL 10

27 30.07.11 5123353 61241942-51 FrameFrame tapping not done & blastinfg on

machined surfaces18

28 30.07.11 5123327 61211803-87-01 Collecting vessel vessel fitment problem with the frame Alok 30


3/67

No action ok

No action OK

To be studied further Pending

100% inspection at supplier end & awareness

given to operator.ok

Tapping will be done w r t 10.2 hole. ok

100% Leak test taken At higher level. Supplier

should send the photos of leak testpending

Awaireness given to operator. ok

100% inspection. Supplier to make a plug gauge

for checking and send a photo to us.pending

ok Reject & scrap at ALIL

Pending Frame is of as per drg.

Informed to supplier to check frame 100% by

special guage ( Mandrel )pending

This frame is from creative &

machining done by Bestall,

instead of RY--Bestall engg.

Doesnt have proper inspection

tools hence problem arised.

Buyer to inform Bestall about this

requirement and start debiting to

Creative if still the problem

continues in future from Bestall

Special guage developent inprocess to check

cover switch holes .pending

Guage will be ready for

inspection till 25/07/11 at

supplier end.

Trials are going on. Jobs as per new dimensions

are ordered.pending Will receive on 1/8/11

To be investigated pending

Awaireness given to operator. ok Ok

To be decided pendingTo be investigate by

Development.

To be investigated pending

Corrective actions taken RemarksStatus


4/67

Threading corrected. ok Ok

To be decided. pending To be investigate

New Drill jig to be made by supplier pendingNew Drill jig to be made by

supplier till ----

Awaireness given to operator/Top part hinge

thickness checked 100% at supplier endok

Informed to supplier to check 100% by gauge ok

Use correct Part. ok

okReject & send back to supplier on

MRV

Blasting & rewok done ok Top part damaged inhouse

Surface made even by griding. ok

Informed to operator & inspector ok

100% check with checking fixture ( Base frame )

at supplier end before dispatch.ok


5/67

Act

01.08.11 512332961207335-

38/61207330-23

v-Belt pulley &

taper lockRunout problem ( 1.2mm ) Imp. ALIL

03.08.11 5123435 61240289-80 Frame 280Eye bolt fitment problem

( Hole shifted )Creative Supplier

03.08.11 5123329 61240010-80 Base frame Horizontal alignment problemCreative/Ry

Ind.Acceptable

03.08.11 5122226 61240369 Plate DamNumber not punched at bottom side of

plate damDynaxcel Supplier

04.08.11 5113350 61240796-81 Frame 450 Blasting done on cladding Bestall ALIL

04.08.11 5123340 ..ECB wrt motor

plateBack drive alignment problem Assembly ALIL

04.08.11 5123329 61240010-80 Base frameBase frame was damaged at the base (

Leg )Crative ALIL

05.08.11 5123314 61230634-80 Frame 450 Frame baffle touches to bowl Bestall Supplier

05.08.11 5111413 61242051-01 Guard Guard fitment problem with Frame Serview ALIL

09.08.11 5123331 61235841-79 Top part 937 Artival no. not punched on top part. ALIL

10.08.11 5123332 61167208-90 O-ring O-ring broken while assembly. Vako

16.08.11 5123400 61204028-15 Damper Height uneven Imp.

17.08.11 5111353 61242127-80 Hub Large End Level tube fitment problem with hub. Tamboli Engg. ALIL

18.08.11 5123317( 440 )

61243749-88 Frame 440 Drilling not done throught the length. Creative/Ry Ind. Supplier

19.08.11 5111353 61241947 Top part Nozzle fitment problem Dynaxcel Supplier

20.08.11 5123476 61242375-80 Frame 200 VFD Alignment problem Srujan Supplier

20.08.11 5123339 61207527-20 Tooth belt pulley Screw slips in tapping Gateej ent. ALIL

CSB QUA

Sr.

No.Date M/C No. Part No. Part Name Problem description

Supplier's

Name

R/W done

by


6/67

22.08.11 5123339 Gasket Less gasket outside the top part slot SD Chemicals ALIL

22.08.11 5123382 61240421-00 Hinge for cover Bracket cover fitment problem Serview ALIL

23.08.11

5123317

( 440 )

61243910-

80/61243749-88

Motor plate &

frame

Gap observed between motor plate &

frame & Creative Supplier

24.08.11 5123360 61241947 Top Part Top part screw fitment problem Dynaxcel ALIL

25.08.11 5123390 61245409-83 Block Block fitment problem Technomech ALIL

27.08.115123318

( 440 )61243993-00 Motor palte 450 Bearing housing fitment problem AKP ALIL

27.08.11 5122218 61243993-01 Bearing housingJacking screw tapping not done for whole

depthAKP ALIL

27.08.11 5123386 61241946-89 FrameBack drive plate fitment problem/ M16

Tapping hole shiftedBestall ALIL

27.08.11 5123346 61230634-81 frame Dowel pin depth problem Bestall ALIL

30.08.11 5123335 61211803-87-01COLLECTING

VESSEL NX418Vessel plate to frame fitment problem Alok Equip. ALIL


7/67

ok

r a a en use

another taper lock,

Pending

Pending

er rame nex

frame will be

Ok

As per Dgr. Plate

dam is ok. We

informed to supplier

--Punch the article

no. at bottom side

ok Debited to supplier

ok

ok

ok

Informed to supplier

to maintain

calculated Dist. 321

between dowellin

ok

ok

ok

s oc o e c ec e

& informed to

Ok er drg. Damper height ok.

Pending. New lot not received.

Pending.

OK Retapping done

OK

Pending Replaced

Status Remarks


8/67

OK Replaced

OK t grinding ( 0.5 - 1 mm )

OK

am er one on

motor plate corner

OK

Pending

Pending parts checked found ok

OK

Pending

n orme to supp er

to check CNC

OK

OK


9/67

1 03.09.11 5123406 61241947-62 Top Part 360

Light gap in rails welded with cover,

resulting --silicon leakage & loose fitment

of gasket

Dynaxcel A

2 02.09.11 5123243 61195636-58 MotorBolt fitment problem with damper--bolt

head strikes with motorABB A

3 05.09.11 5123243 61243749-33 Frame 440 Electrical wiring problem to Frame Creative & RY A

4 05.09.11 5123407 61242248-01 Driver Driver does not have slot Micro-India A

5 05.09.11 5123297 61243816-02 Flange with gutter Fitment problem Arni-mech. A

6 05.09.115123387 &

511135461242742-80 Centraflex coupling Found burr inside the coupling Vulkan A

7 06.09.11 5123387 61241993-80 Back Drive, Plate Earthing screw broken Technomech A

8 07.09.11 5123520 61240424-01 Bracket machined Fitment problem Mhalsakant A

9 08.09.11 5123243 61243749-33 Frame 440 Wear liner fitement problem Creative & RY A

10 10.09.11 5123408 61241958-42 Frame backdrive alignment problem Bestall Sup

11 10.09.11 5127430 61235390-01 Motor plate Back drive alignment problem Technomech A

12 12.09.11 5111432 O-ring Fitment problem Vako

13 12.09.11 512346/5123388 61242533-80 Hinge for cover Fitment problem Ganesh Engg. A

14 12.09.11 5111432 61235390-01 Moter plate / frameBack drive plate with frame fitment

problem

Technomech /

BestallA

15 13.09.11 5123455 61240010-80 Base frame Incomplete reaming Creative & RY A

16 14.09.11 5123455 61232699-01 CoverBearing cover fitment problem with

housingAKP A

Sr. No. Date M/C No. Part No. Part Name Problem description Supplier's NameR/W

b


10/67

18 14.09.11 5123453 450 61239619-01 Back Drive, Plate Back drive plate having uneven surface Technomech

19 15.09.11 5123337 61235371/5372-80 Guard Guard fitment problem with the frameBharat

Fabrication

20 15.09.11 5123297 440 61243749-44 Frame Solid funnel fitment problem Creative & RY

21 19.09.11 5123409 61241942-58 Frame 360 back drive alignment problem Bestall B

22 19.09.11 5123416 61241942-79 Frame 361 At frame feet welding not done Bestall B

23 19.09.11 5123479 61241947-44 Top Part 360Top fitment problem /Top part baffle

touches to bearing housingDynaxcel Dy

25 20.09.11 5123409 61241942-58 Frame 360 Solid funnel fitment problem Bestall

26 21.09.11 5123289 61241993-80 Back Drive, Plate back drive plate fitment problem Technomech

27 21.09.11 5123397 61241946-89 Frame 360 Gutter fitment problem Bestall

28 23.09.11 5123465 61241942-81 Frame 036Main drive fitment problem to frame/

Pulley touches to frame netCreative Cr

29 23.09.11 5123565 61239831-01 Inlet pipe support Inlet tube baracket fitment problem AKP

30 23.09.11 5123565 ( 200 ) 61239783-82 Top part 200Key strikes the top part during back drive

motor rotationSrujan

31 24.09.11 5111433 61241947-41 Top part 360 Top part baffle touches to Bearing housing Dynaxcel

32 24.09.11 5123402 440 61243751-96 Frame 440 Seal ring fitment problem to frame Creative

33 24.09.11 5123402 61243759-65 Top part 441 Cover gutter fitment problem Dynaxcel

34 26.09.11 5123660 Flange for ECBFlange for ECB fitment problem with the

frame

35 26.09.11 5123398 61241946-89 Frame 360 Seal ring damage during assembly Creative

36 26.09.11 5111441 61242754-81 Frame 361 Baffle & bowl having less gap Bestall

37 26.09.11 5123560 61240289-81 Frame Back drive plate fitment problem ( tapping ) Bestall

38 26.09.11 5123606 61239831-01 Inlet pipe supportFeeed tube strikes the inside bore of

Conveyor.AKP

41 27.09.11 5123500 61240289-81 Frame 280 VLM drilling not on the frame Srujan Su

42 29.09.11 5123424 61241947-41 Top part 360 Top part leakage problem. Dynaxcel

43 28.09.11 5123398 61241946-89 Frameframe having blow hole /At inlet radius is

unevenCreative

44 29.09.11 5123472 61242132-74 Top part Nozzle fitment problem with the top part Dynaxcel

45 29.09.11 5123560 61240289-81 Frame 280Electrical bracket fitment problem with the

frameSrujan


11/67

46 30.09.11 5123426 61241972-01 Cover bearing cover issued without tapping. Arni-mech.

47 30.09.11 5123456 61211803-87-01 VesselVessel req. M6 tapping but tapping done

M4Alok A


12/67

Inform to suppier to maintain spot welding &

fusing distances correctly.Ok Rewokdone

Pending grinding ( Rework done )

Pending

Inform to supplier to check 100 % beforedispatch.

Ok Replaced.

Reject & sent back to supplier OKJobs as per old revision no. was

lying in the stock

Informed to supplier to clean the job before

dispatch.Ok

Informed to supplier to use proper studs (

Material )Ok

Instructed to supplier to chech bore afterpainting

Ok

Special checking gauge will be developed by

CMA and used for in-process inspection. Target

date - 16.09.2011

Pending

New gauge to be develop by supplier Pending Rejected & sent back to supplier

Informe to supplier ok

pending As per drg. O-ring ok.

Tapping reference to be changed Pending

Instruction given to assembly person to apply

lubricant while pin assembly.ok

Communicated to supplier regarding reamer

depthOk

Informed to supplier. Ok

Corrective actions taken Status Remarks


13/67

Instructed to supplier to use proper raw

materialok

Pending Gap uneven--Fitment ok

Istructed to supplier to check funnel tapping

100 % Ok Retapping done

Machine calibration Ok Rejected sent back to supplier

Informed for proper visual inspection. Ok Rework done

Inform to reduce shrinkage in welding by

proper holdingOk Rework done

Istructed to supplier to check funnel tapping

100 %OK

issue motor plate by conforming art. No. OK

OK seen by Mahajan Sir

All bar corrected as per drawing. Ok Grinding r/w done

Pattern corrected Ok Grinding r/w done

Radius corrected wrt center ( check point added

)Ok

Inform to supplier to check 100 % before

dispatch.Ok

Pending

Pending

OK Used hold frame for assembly.

After machining calculated dist. To be

maintained by supplierOK

Informed to supplier. OK

Pattern corrected OK Grinding r/w done

latest drawing given to supplier. OK Inhouse rw done

Inform to reduce warpage in welding. OK

Pending

Instructed to clean the threading before

assembly.Ok

Instructed to use gauge for drilling tapping &

reduce manual error.Pending


14/67

Informed to supplier. OK

Instructed to reffer drawings while performing

operationsOK


15/67

1 07.10.11 5123496 61237229-21 Taper Lock

2 08.10.11 5123417 61242132-83 Top part sticker

3 08.10.11 5123515 61241946-83 Frame

4 08.10.11 5111443 61242754-81 Frame 450

5 10.10.11 5123458 61241803-87-01 Vessel 353

6 11.10.11 5123496 61242017-81 Feed tube

7 12.10.11 512345961207335-25/61207333-

19Pulley/Taper lock

8 13.10.11 5123358 61243764-81 Upper casing

9 13.10.11 5123419 61242171-80 Level tube

10 13.10.11 5111444

11 14.10.11 5123482

12 17.10.11 5123433 61242132-83 Upper casing

13 17.10.11 5123522 61241942-61 Frame

14 18..10.11 5123509 61239619-01 Motor plate

15 18.10.11 5123482 61235841-80 Upper casing

16 18.10.11 5111463

17 18.10.11 5123514 61241947-62 Cover

18 18.10.11 5123433 61242132-83 Upper casing

19 19.10.11 5123341 Coupling

20 19.10.11 5123509 61238026-02 Fibre glass guard

Sr. No. Date M/C No. Part No. Part Name


16/67

21 19.10.11 5111463 61241947-49 Upper casing

22 19.10.11 5123358 61243693-01 Bearing Housing

23 20.10.11 5123552 Frame

24 21.10.11 5123498 61236296-80 Guard

25 21.10.11 5123451

26 21.10.11 5123452

27 24.10.11 5123452

28 24.10.11 5123454 61211803-87-01COLLECTING

VESSEL NX418


17/67

Actual Rework

min

Key fitment problem with taper lock.

Key fits jam in taper lock.Sankalp Engg. ALIL 10

V is missing in logo 'ALFALAVAL ' Dynaxcel ALIL 120

Bowl does not start in frame due to

gutter ring.Bestall Supplier 240

O-ring for flange with gutter & cover

fitment problem.Bestall ALIL 15

Bowl groove strikes with vessel

baffleAlok ALIL 10

Inlet tube & O-ring fitment problem Serview ALIL 0

main drive pulley group----61207335

25 SPZ V-belt pulley 250 having

high runout value.

CMB ALIL 15

Top part bolt fitment problem Dynaxcel

Level tube fitment problem. Zeal Ent. ALIL 15

Bearing housing for small end having

blow holes.

Bearing housing issued with blow

hloes.AKP ALIL 0

Nozzle fitment problem with toppart.

Dynaxcel Supplier 15

Torque arm assembly fitment

problemBestall ALIL 30

Back drive plate fitment problem Technomech Supplier 30

Top part leakage Dynaxcel Dynaxcel 10

Sensor & bracket fitment problem 10

Top part blasting not done properly/

rust obs. Dynaxcel ALIL 60

Top part leakage Dynaxcel ALIL 10

Gearbox shaft to coupling fitment

problem.Vulkan Vulkan 15

Fibre glass guard rubber bush

fitment problem.Onkar Supplier 15

CSB QUALITY PRO

Problem description Supplier's Name R/W done by


18/67

Top part leakage Dynaxcel Supplier 30

Dowel pin tightning problem--During

tightning, socket strikes with bearing

housing.

AKP ALIL 30

Junction box hole not on the frame

Guard cutting not done properly Shakti-N Mack ALIL

Throught drilling not done for

alignment holes.10

Vessel fitment problem with Frame

& gasket found less.

Bolt fitment problem between

Vessel arm & Frame

Vessel fitment problem with Frame. Alok Equip. 60


19/67

Machine delay

minTotal Rework min

0 10 Taper conversion not proper

0 120 sticker time --after pasting not taken beforeblasting/ 'V' removed in blasting.

0 240tap was broken in gutter radius & high points of

welding on gutter radius.

0 15 Blasting on machined radius area.

0 10 Baffle extra bend obs. In handeling

0 0

0 15High points obs. on taper of taper lock./Claning not

proper

Design error in top part ( Red DN received )

0 15 Rust inside the tapping.

0

0 0 Acceptable

240 255 Threading damage in handeling

0 30Manual marking --referance not taken properly (

From machining ). Tapping holes not drilled in line.

0 30 CD 610 mm obs. u/s by 0.2

0 10 Pin hole in welding

10 20 Bracket bend obs.

240 300Grinding burr striked on this top part, while

reworking another top part

360 370 Welding crack obs.

0 15 zink plated alu-passivation layer inside the bore.

0 15 Putty & paint inside he paint.

Root causes analysis

BLEMSRework Hrs


20/67

360 390 Welding crack obs.

0 30

0

0

0 10

0

0

0 60

32.66666667


21/67

No conversion or conversion as per drawing. OK Taper lock changed.

Stcker pasting time to be maintained & afterblasting sticker to be inspected.

OK R/w at ALIL by supplier.

M4 screw fitted with the frame ( In gutter

radiu ), will receive from next lot.Ok

Machined area( radius ) to be protected from

blasting.Ok manualy polished.

Informed to supplier for proper handeling Ok

Under investigation PendingAS per drawing both part

are OK.

Before assely clean taper lock & pulley

tapered area propely.oK Taper lock replaced.

Design changed. oK

Informed to supplier oK Cleaned by air.

OK MRV

Acceptable

Informed to supplier for proper handeling OK Retapping done

Gauge to be developed Pending Rewok done

Center drill to be used from next batch. OkPlate changed, fitment

ok.

instructed to welder for proper welding. Ok

Instructed for proper clamping in welding. OK Rework done

Proper covering to be done while rework.. OK

Awaireness given to welder Pending Debited to supplier

plain plug gauge developed for bore checking. OK

Gauge developed, Ok Rework done for all stock

Corrective actions taken Status Remarks


22/67

Awaireness given to welder PendingDebited to supplier -

dynaxcel


23/67

1 01.11.11 5123466 61211803-87-01 Collecting vessel

2 02.11.11 5123454 ( 353 ) 61240011-83 Sub Frame


4 02.11.11 5123466 00533019-02-01 Bearing holder

5 02.11.11 5123449 61241993-80 Motor plate

6 02.11.11 5123467 61240010-80 Base Frame

7 03.11.11 5123391 ( 440 ) 61242802-08

Bracket for al

control.

8 03.11.11 5123446 61207330-17 Taper lock



24/67

9 04.11.11 5123485 61235841-80 Top part PANX


11 05.11.11 R5110218 61240054-01 Bearing housing

12 07.11.11 5123486 61207537-01 Shaft

13 07.11.11 5123449

14 07.11.11 5123532 61242048-04 V-Belt pulley


16 08.11.11 5123461 61240321-83 Centraflex coupling

17 08.11.11 5123449 61242132-83 Top part


25/67

18 08.11.11 5123319 61243749-44 Frame

19 10.11.11 5123280 61243749-20 Frame

20 10.11.11 5123466 61240011-83 Sub Frame

21 11.11.11 5123543 61211803-87-01 Collecting Vessel

22 11.11.11 5123319 61195011-80 Ball Bearing

23 14.11.11 5123342 61241972-01Cover for bearing

housing

24 14.11.11 512348661235841-

80/61239398-82Cover & frame

25 15.11.11 5123280 61241947-40 Cover

26 15.11.11 5123486 61235841-80 Upper casing

27 15.11.11 5123577 61241947-40 Upper casing


26/67

28 16.11.11 61236296-01 450 Guard

29 17.11.11 5111456 61243759-51 Cover

30 17.11.11 5111456 61243749-25 Frame

31 17.11.11 5123342 61243739-96 Frame

32 18.11.11 5123342 61243964-01 Outlet funnel

33 18.11.11 5123544 ( 353 ) 61240010-80Frame LYNX &

Motor.

34 18.11.11 5123392 61244139-01 Guard.

35 19.11.11 5123405 61242540-02 Washer

36 19.11.11 5123504 61241942-69 Frame

37 19.11.11 5123607 61240397-80 Motor plate

38 21.11.11 61236296-80 Guard 450

39 21.11.11 61243759-44 440 Top part.

40 22.11.11 5123507 61242132-92 Top part


27/67

41 22.11.11 5123405 61243759-65 Top part

42 22.11.11 61231942-51 Frame

43 23.11.11 3.5 DD Gearbox. 61240885-01 Sunwheel shaft

44 24.11.11 5123405 ( 440 ) 61244218-80 Motor palte

45 24.11.11 5123578 61211740-03 ECB

46 24.11.11 5123504 ( 440 ) 61243749-20 Frame

47 24.11.11 8KNM DD Gearbox

48 25.11.11 360 Cover 61241947-50 Cover

49 26.11.11 5123573 61167219-81 O-ring.


28/67

Actual

Rework min

Machine

delay min

Vessel fitment problem with the frame Alok Supplier 120 0

Earthing nut missed. Creative ALIL 10 0


Bearing holder fitmrnt problem with wear

bush.Mhalsakant Supplier 0 0

Back drive plate CD does not match with the

frameTechnomech ALIL 0 0

Legs of Base frame was damaged. Creative Supplier 30 0

Bracket for torque arm having high points in

it. Sanjivani ALIL 15 0

Taper lock used without Blackwadising Kvissgaard 0 0

Supplier's NameR/W done

by

Rework Hrs

Problem description


29/67

Top part bolt fitment problem with frame Dynaxcel Supplier 120 0


Loose fitment of bearing & bearing housing. AKP .. 0 0

Bearing rotates freely on shaft Mhalsakant ALIL 10 0

Main bearing pulley & bearing housing

rubbing problem.30 0

Main drive pulley --Balancing weight falling

problem.CMB ALIL 30 0

Vessel & sub frame fitment problem ALOK Supplier 120 0

Pin broken Kvissgaard 10 0

Top part hole not machining Dynaxcel ALIL 120 0


30/67

Drilling not done throughout at Gland

location.Creative Supplier 20 0

Wear screen fitment problem Creative Supplier 240 0

Electrical plate fitment problem. ALIL 0 0

Vessel fitment problem with the frame Alok ALIL 120 0

Bearing rotates freely in housing. SKF

Blow holes to Cover for Bearing housing Arni-Mech 10 0

Gutter not maching. ALIL ALIL 0 0

Rust spots on cover ( gear side ) Dynaxcel ALIL 0 0


Top part touches to Bearing housing. Dynaxcel ALIL 15 0


31/67

Cutting not done properly. Shakti-N-Mach Supplier 10 30


M8 x 12 tapping strip not welded Creative Supplier 90 0

During RA mounting in a frame, bearing

housing strikes with the frame.Creative ALIL 30 0

Funnel fitment problem with the frame Serview Serview 240 240

Back drive alignment problem. Baldor. ALIL 0 0

Guard fitment problem--Making noise in

testing.Serview ALIL 10 0

Washer fitment problem with actuator arm. Ganesh Engg. Supplier 10 0

RA does not rotate in frame ( Fitted ) Creative ALIL 60 0

Motor plate fitment problem with motor. Technomech Supplier 45 0

Guard without end plate proper laser cutting

not done.Shakti-N-Mach ALIL 15 0

Hinge pin fitment problem. Dynaxcel ALIL 10 10

Top hole not matching. Dynaxcel Assembly. 15 0


32/67

Top hole not matching. Dynaxcel Assembly. 165 0

Frame CD 490 obs. 500 mm creative Supplier 120 0

Sun wheel shaft machined ,PCD problem,Not

maching.Grindel. ALIL 10 0

Gap obs. Between motor plate & Frame. Technomech ALIL 0 0

Back drive alignment problem. Torspec ALIL 180 0

Wear screen fitment problem. Creative ALIL 30 0

Cover rusty. Prashtech. 10 0

Waviness in gasket rail. Dynaxcel ALIL 10 0

O-ring cuts during assembly. Vako ALIL 30 0


33/67

Total

Rework min

120 Base weared out of checking fixture

1)Fixture R/W done on 15-11-11 . 2)

100% inspection by feeler gauge for gap

between base of vessel & frame assembly

at Alok. 3)

To avoid chances of resting lug warpage

after glass blasting in ALIL Alok will supply

vessel with glass blasting

OK

10 Opration missed.Awareness given to weider & check point

added in PDIR.OK


1)Fixture R/W done on 15-11-11 . 2)100% inspection by feeler gauge for gap


at Alok. 3)




OK

0 As per drg ok. used for another machine OK

0 Wrong motor plate issued OK Ok

30Handeling damage in blasting or

painting .

Handeling process improved & higher side

thickness channel to be used.Ok

15 Casting high points Inform to supplier to remove high points . Ok

0 Ok as per supplier standard.Inform to buyer to purchase from CMB or

Local.OK

Root causes analysis Corrective actions taken Status


34/67

120Bow / Welding warpage observed &

not checked properly.

New gauge to be developed. Gauge

design & manufacturing discussion will be

between dynaxcel & ALIL on 16.12.11.

Pending

120 Base weared out of checking fixture.




at Alok. 3)




OK

0 Ok as per drg. OK OK

10 Shaft is ok as per drg. OK Ok

30 To be investigate Ok

30Screw which holds balance weight

breaks downInformed to supplier

Pending --

wating for

next ok lot





at Alok. 3)




Ok

10

Pin assembled with coupling by special

locktite

Informed to supplier to despatch --Loose

parts of coupling. OK






Pending


35/67

20Operator mistake & not checked

properly.Guage developed for checking. Ok

240Welding fixture not used properly &

checking fixture not available.

1) Proper use of welding fixture &

checking fixture developed on 10/12/11

OK

0 BOM error Special palte made for subfarmae OK





at Alok. 3)

To avoid chances of resting lug warpageafter glass blasting in ALIL Alok will supply


Ok

Acceptable OK

10 Casting defectInformed for 100% inspection for blow

holes.OK

0 Proper alignment not done. Awareness given to assembly person.. OK

0 Improper cleaning after acid cleaningSoap water cleaning added after acid

cleaningOK

90

Bow / Welding warpage observed &



design & manufacturing discussion will bebetween dynaxcel & ALIL on 16.12.11.

Pending

15 Welding warpageCheck 100% on fixture both side 1 mm

gap maintained.OK


36/67

40 Improper laser cutting.Instructed to supplier for proper laser

cutting.OK






Pending

90 Negligence to workAwareness given to worker & point added

in checklist.Pending

30 To be investigate Pending

480 Dimn. 13.00 obs. 5-16 mm of Funnel Check point added. OK

0For alignment hole clearance not

sufficientCR to be raise Pending.

10 Improper assembly Awareness given to assembly person.. OK

0 ID Of washer U/S by 0.2 mm. Gauge developed for checking ID. OK

60

Machining supplier changed. Frame

fabricated in Creative & machined in

bestall.

c ec or rame y spec a

mandrel. New mandrel will develop at

bestall also & point added in Bestall QITOK

45Locating ID u/s by 0.5-0.6. Error in

checking instruments.caliberation done & error removed. OK

15 Improper laser cutting.Instructed to supplier for proper laser

cutting.OK

20 Hinge hole dia. u/s Gauge developed for hole Diameter. OK






Pending


37/67






Pending

120 manual marking done fixture to be developed. Pending

10 ( Imported item ) OK

0 Welding warpage in Motor plate.Flatness added on drawing & given to

supplier.OK

180 Dist. 132.00 ( -0.2 ) obs. 132.194Informed to supplier & supplier agreed to

maiantain this disd. Lower sideOK

30

Welding fixture not used properly &

checking fixture not available.

1) Proper use of welding fixture &

checking fixture developed on 10/12/11 OK

10 Old batch job Rust removed. OK

10Handeling damage in specific area of

rail.Awaireness given to supplier. OK

30 To be investigate Pending

46.1666667


38/67

Fixture rework done

on 15/11/11. Alok

will buy new blasting

maching & install

from Feb-12

R/W done

Fixture rework done

on 15/11/11. Alok


maching & install

from Feb-12

As per drg. Bearing

holder ok.

Motor plate

replaced.

Acceptable

Remarks


39/67

Fixture rework done

on 15/11/11. Alok


maching & install

from Feb-12

Parts checked OK as

per drg.

Fixture rework done

on 15/11/11. Alok


maching & install

from Feb-12

Old stock


40/67

Action completed &

waiting for Next lot

Action completed

Special plate

Fixture rework done

on 15/11/11. Alok


maching & installfrom Feb-12

As per drawing both

parts ok

Rejected & sent

back.

Raw material is ok

Rework done.


41/67

Rework done

Action completed &

waiting for Next lot

Rework done

Rework done by

Suppiler.

Rework done


42/67

Target Date

17/12/11

MRV taken

Action completed


43/67

02.12.11 5123657 61240495-81 Cover

02.12.11 5123604 61207330-41 Taper lock.

02.12.11 5123471 61239333-02 Guard

02.12.11 5123527 61235841-80 Upper casing

07.12.11 5123488 61239398-82 Frame

06.12.11 3.5 Gearbox Sunwheel

06.12.11 5123493 61240053-01 Bearing Housing

05.12.11 5123615 Actuator arm

06.12.11 5123493 61211803-87-01 Collecting vessel

06.12.11 5123527 61242535-85 Funnel & Frame


03.12.11 5123493 61240010-80 Frame



44/67

` 5123641 61241947-50 Cover


12.12.11 5123436 61240797-81 Frame

13.12.11 5123593 61240010-80 base Frame

08.12.11 5123555 Gearbox Adapter

10.12.11 5111475 Funnel

08.12.11 5123488 61239398-82 Frame


10.12.11 5123528 61239398-82 Frame

15.12.11 5123593 61240010-80 base Frame

14.12.11 5123612 61243749-85 Frame


17.12.11 5123579 61243759-44 Cover

17.12.11 5111451 61207537-01 Counter shaft


45/67

19.12.11 5123489

14.12.11 5123593 61240010-80 Frame

17.12.11 5123645 61241947-44 Cover

17.12.11 5123644 61241947-44 Cover

19.12.11 5123580 61244160-80 Motor plate

17.12.11

61241947-50 Cover

17.12.11 5123594 61240010-80 Frame

14.12.11 5123511 61243761-84 Cover

15.12.11 5123593 61240292-01 Motor plate

14.12.11 5123477 Circlip

26.12.11 5123623 61243759-53 Cover

27.12.11 5123490 61233609 Guard

28.12.11 5123531 61242004-01Shaft for conveyor

bearing.

31.12.11 5123427 61244138-01 Weal Liner


46/67

29.12.11 5123646 61243759-53 Upper casing

27.12.11 5123664 61204028-19 Vib. Damper

31.12.11 5123427 61242533-81 Hinge for cover

29.12.11 5123530 61207537-01 Shaft

28.12.11 Gear box 8 Knm Sunwheel Shaft


47/67

Actual

Rework

min

Machine

delay min

Blasting not done from one side. Srujan ALIL 60 0

Fitment problem with pulley. CMB ALIL 5 0

Rubber bush fitment problem. Onkar Udyog ALIL 15 0

Top part holes not matching. Dynaxcel ALIL 180 0

Small spatters found on the frame Bestall ALIL 15 0

Dents. ALIL 10 0

Uneven surface area. AKP ALIL 0 0

M12x25 Tapping problem Ganesh Engg. ALIL 3 0

Wear liner fitment problem. Alok ALIL 10 0

Water leakage from funnel Serview & Bestall ALIL 60 0

Blow holes on leg/resting area. Alok ALIL 15 0

Frame alignment problem. Creative ALIL 0 0

Supplier's Name R/W done by

Rework H

Problem description


48/67

Top part holes not matching. Dynaxcel ALIL 15 0

Vessel cover touches to bowl Alok ALIL 60 0

Frame having uneven surface of foot section. Bestall Supplier 15 0

Reaming not done for base frame. Creative ALIL 10 0

Adapter fitment problem to hub, Holes not

matching.Shree Engg. 0 0 0

Fiunnel; fitment problem. Serview Supplier 15 0

Guard fitment problem with the Frame. Bestall ALIL 10 0

Vessel cover touches to bowl. Alok ALIL 60 0

Gutter ring fitment problem with the frame. Bestall supplier 0 0

Back drive alignment problem. Creative ALIL 180 0

Earthining screw fitment problem. Creative ALIL 10 0

Vessel to frame hole mismatch. Alok ALIL 10 0

Top part leakage. Dynaxcel ALIL 0 0

Countershaft plate fitmrnt problem. Mhalsakant ALIL 0 0


49/67

Tooth belt pulley fitment poblem. Gateej Ent. 10 0

For base frame blow hole found on M16

tapping./ Counter drill shifted.Creative Supplier 10 0

Top part holes not matchining. Dynaxcel ALIL 15 0

Top part fitment problem---Baffle touches to

bearing hgs.Dynaxcel Supplier 30 0

wrong motor plate issued on article number

61244160-80.Technomech Supplier 20 0

360 top part--pin fitment problem Dynaxcel ALIL 10 0

Bottom surface of base frame for 4 leg having

uneven surface area.Creative Supplier 30 0

Top part holes not matchining. Dynaxcel ALIL 90 0

Cross tapping to motor palte. Technomech ALIL 30 0

Counter shaft having circlip fitment problem. Imported. ALIL 10 0

Top part fitment problem with the frame Dynaxcel ALIL 60 0

Main drive guard hole shift Serview ALIL 5 0

In counter hole found welding. Shree Engg. ALIL 15 0

wear screen fitment problem with the frame Serview ALIL 10 0


50/67

Top part pin fitment problem. Dynaxcel ALIL 10 0

Back drive alignment problem after bolt

tightining. Alignment varies upto 1 mm.Imported. ALIL 15 0

Hinge for cover fitment problem with the top

part. Ganesh Engg. ALIL 5 0

Shaft fitment problem with the pulley. Mhalsakant ALIL 0 0

Sunwheel having hign dents. Imported. ALIL 5 0


51/67

Total

Rework

min

60 Operation missed./operator not trained. Training & awareness given to operator

5 Ok as per drawing. Ok

15 Paint/putty inside the hole.Special guage developed for hole

checking.

180 Not checked properly on fixture. Instructed for 100% check on fixture.

15 Welding spatters. Awareness given to welder.

10 Handeling damage.

0 Excess grinding. Pattern corrected.

3 Threading start damaged. Check 100% by gauge.

10 Liner bending not proper done. Check point added in PDIR for bending.

60 to be investigate

15 Defective piece welded.Awaireness given to welder before

welding check visually.

0 Ok as per drawing. Ok

s

Root causes analysis Corrective actions taken


52/67

15 Not checked properly on fixture. Instructed for 100% check on fixture.

60 to be investigate Stock checked by checking fixture.

15 Dents obs./Handeling not proper. To be decided.

10Reamer not passed through the hole, Light

step obs. At the end of hole.Instruction given to operator.

0 Not proper guiding /Alignment done. Ok

15 Hole CD u/s by 2 mm /Welding warpage Check 100% by gauge.

10 Frame CD u/s by 1 mm.

60 To be investigate Stock checked by checking fixture.

0 Ok as per drawing. OK

180Not sufficient clearance for

adjustment/Alignment ( Baldor Motor ).

Trial to be taken for alignment ( Motor

fitment holes to be checked on machine

at supplier ).

10 Threading start damaged. special caps to be develop for threading.

10 Welding warpage.

x ure one on - - .

2) 100% inspection by feeler gauge for

gap between base of vessel & frame

0 No leakage OK

0 AS per drawing shaft OD ok. Ok


53/67

10 ID 62.00 o/s by 0.015mm

10Power failure while machining./Counter drill

shiftedCorrected as per drawing

15Bow / Welding warpage observed & not

checked properly.



between dynaxcel & ALIL

30 Baffle bend obs.Instructed for 100% check for baffle in ----

right angle

20

Wrong punchining done on motor plate &

Physically motor was 61243910-80, punchining

done as 61244160-80.

Check point added in PDIR

10 Diameter found to lower side & burr obs. New pin given to supplier for checking.

30 Handeling damage in blasting or painting .Handeling process improved & higher

side thickness channel to be used.

90Bow / Welding warpage observed & not

checked properly.




30 Manual tapping done. Tapping required to done on machine.

10 Excess deformed. Stock checked.

60 Hinge not in right angle




5Problem in screw ( Not in guard )--Screw start

damaged. All stokk checked.

15 Blow hole reworkedCheck point added in PDIR for heatmark

& spatters.

10 Wear screen twist. Check point added for twist in PDIR.


54/67

10 Diameter found to lower side & burr obs. New pin given to supplier for checking.

15 Damper problem/Trial to be taken Ok

5 As per drawing part ok.

Refferance change drawing given to

supplier.

0 Part ok as per drawing. Ok

5 Handling Damage All stokk checked.

0

0

18.96667


55/67

OK Inhouse blasting done. Just do it

OK Reassembled & found ok. Just do it

OK DMAIC Express Nilesh Dubal

OkTwo holes was mismached--

Inhouse grinding done.Just do it

OK Just do it

Pending

Ok Accepted. DMAIC Express Kishor Gadge

OK Retapping done. Just do it

Pending Just do it

PendingLeakage from only one

screw.

OK Just do it

Ok Accepted.

Resolution

method

Project

ManagerRemarksStatus


56/67

Ok Just do it

Pending

Pending

Ok Just do it

OK

OK

Pending One hole mismatch.

OK Rework done

OK Accepted.

Pending Rework done inhouse

Just do it

Pending Rework done inhouse DMAIC Express Nilesh Dubal

OK One hole missmatch.Just do it

OK

Just do it

Ok Shaft od found lower side.


57/67

OK Rejected

OK No blow holes & accepted.

Pending Rework done inhouse

Ok Rework done inhouse

OK Stock checked.

OK

OK Rework done

Pending Rework done

Pending Rejected.

OK Only one piece.

pending Rework done

OK Rework done

OK Rework done

OkRejected & sent back to

supplier.


58/67

Ok Rework done

Ok As per drawing pwrt ok.

OK

For M8 tapping hole rework

done

OK

OK Rework done


59/67

Month

Jul-11Aug-11

Sep-11

Oct-11

Nov-11

0

5

10

15

20

25

30

35

40

45

50

Jul-11


60/67


61/67

Hours.

27.623

25.5

32.6

46

Assembly R/w hrs. due to receipt ( Supplier ) quality parts.

Aug-11 Sep-11 Oct-11

R/w due to supplier quality parts


62/67

Corrective action

No action, Someone else to handle or referring to "further investigation".

"Talked to", Informed or refering to ongoing project.

Procedure identified, SOP, Procedure , drawing. Documentation changed or training made on existing documente

New or changed procedure , verified by responsible managerand/or test.

New or changed procedure is communicated, control plan or POKA YOKE / fail safe solution in place.


63/67

Supplierwise total r/w line & total r/w H

Supplier NameNo. of r/w

lines

Creative comb. 9Dynaxcel 10

Alok Equip. 5

Serview Ent. 2

Torspec 1

Shakt-N-mach 2

Technomech 3

CMB 1

Vako 1

Sanjivani cast. 1

Kvissgaard 2

Prashtech 1

Grindel 1

Arni-Mech 1

Nov-11

Hours.

0

2

4

6

8

10

12


64/67

Rating General Hit rate

0

1

2

3

4

0

1


65/67

s. for Nov.11

Total r/w time

(hrs.)

10.510.25

10

8.16

3

0.91

0.75

0.5

0.5

0.25

0.16

0.16

0.16

0.16

No. of r/w lines

Total r/w time (hrs.)


66/67

1 10.06.13 5124770 Creative MechFrame -

61243749-89

Frame CD ( 200mm ) of guard fitment

shifted.Drilling Not

Sr.

No.Date Machine No Supplier name Part Name & No.

CSB QUALITY PROBLEMS

Problem Description Problem Photos

Category of

operation

mistake

Categ

inspe

pro


67/67

Drilling Checked by Fitting

GuardQuality 20.06.2013

Using Fixture For

Drilling

Carefully using

Fixture for drilling

Production

Operation standard

before

Production Operation

standard after (

Complitation date )

Inspection standard

before

In

afCorrective & Preventive Action

PlanResponsibility Target Date

C:\Documents andSettings\Administra

C:\DSettin