rv3 koel quality issue- srf action... plan 14 08 15 a

Shriram Foundry Ltd. Kolhapur, India.

Zanvar Group of Industries

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ACTION PLAN FOR RECENT QUALITY ISSUE OBSERVED AT KOEL KAGAL IN

MONTH OF JULY 2015.



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Action plan & effectiveness KOEL – Crank Case



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DefectProblem – Sand wash/inclusion at drag side body & oil gallery.



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1) Found weak sand at ingate from core area. 2) Mould erosion found at pouring bar & runner bar.3) Sand drop near side core touch prints. (Gear end & flywheel end area)

ACTION PLAN:-1) Fillet radius at ingate from core. (dtd. 19/07/15)2) Special sand used near pouring bar & runner bar. (dtd. 19/07/15)3) Shell core provided for runner bar to avoid green sand erosion. (10 nos. Samples dtd. 28/07/15)4) Additional gas vents provided at 4 places. (dtd. 19/07/15)5) Gear & flywheel end cores prints to extended by 40 mm. ( dtd.- 5/08/15) 6) 2 nos. Gas vents at gear end & height & dia. increased. 7) 3 nos. gas vents crank case bore & height increased.

ROOT CAUSE ANALYSIS :-

Defect-: - Pin holes, Sand wash/inclusion at drag side body & oil gallery.



Gas vent height increased up toMould box height. Dtd. 28/07/15

Gear end & flywheel end gas vent height increased up to Mould box height. Dtd. 13/08/15



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Side prints extended by 40 mm. Targeted core wt. increased 3.8 kg.

Gear & flywheel end cores prints extended by 40 mm. (dated- 5/08/15)To avoid sand drop.



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Monthly production

Jan-15 Feb-15 Mar-15Apr-15May-15Jun-15 Jul-150

200400600800

10001200140016001800

348 386

9831196

12941474

1605

Foundry total production Qty.

Total production Qty.

Month

Prod

uctio

n Q

ty.

Jan-15

Feb-15

Mar-15

Apr-15

May-15

Jun-15Jul-1

50

200400600800

100012001400

473569

8091017

1269

991

1300Machine shop total production Qty.

Total production Qty.

Month

Prod

uctio

n Q

ty

Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15 Jul-150

200

400

600

800

1000

1200

1400

535

192

865

1034

1387

1067

1289

Machine shop total dispatch Qty.

Total dispatch Qty.

Month

Tot

al d

ispat

ch Q

ty.



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Monthly rejection

Jan-2015

Feb-15 Mar-15 Apr-15 May-15 Jun-15 Jul-15 Aug 15-till date0

5

10

15

20

25

22.6

15.6

19.11

11.9611.14

10.1411.27

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Total rejection %

Series1



9

0

2

4

6

8

10

12

10.94

5.72

Foundry stage rejection % July 2015

Total Rejection %

Rejection before & after cut off date – 14/07/15

After cut o

ff

date Before cut off date

After cut off date

1

1.2

1.4

1.6

1.8

2

2.2

2.42.4

2.52

Machine shop stage rejection % July 2015

Total rejection %

13.34

8.24

Total rejection % July 2015

Total rejection %



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Part Name: RV3 Crank-CasePart No :- 39.185.01.0.00

CUSTOMER REPORTED PROBLEM -:



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Customer Name KOEL

Product Name & Part No. RV3 Crank-Case 39.185.01.0.00

What Happen ? Thrust Cap Width observed undersize i.e.29.74 against 29.81

Why it is a Problem? Pl. refer next slide

When did it happen? 15/07/2015Where it has been detected? KOEL Receipt QAWho has detected it? KOEL Receipt QA

How it has been detected? During Inspection with Micrometer

How many detected? 1 Nos. in batch of 48 Nos.Recurrence YES

Identify The Problem

Defect-: Thrust BRG cap width specified 29.81 to 29.84mm & observed o/s & u/s



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ROOT CAUSE ANALYSIS:- This is machine Aging effect. Thrust cap width observed o/s due to surface grinder table taper within 0.030 to 0.120mm (total bed taper is within 0.04 to 0.40mm) & size not maintained within given allowance.

SHORT TERM ACTION PLAN:-

For time being we had taken additional 0.250mm Magnetic table cut to reduce the taper of bed. Also KOEL has given deviation within 29.76 to 29.84mm considering condition of machine & bed taper. So It has been decided to maintain the size as per deviation received from KOEL until New machine not received for MB cap grinding operation & which is permanent action to eliminate this quality issue.

PERMENANT ACTION PLAN:-

KOEL has sanctioned the requirement for replacement of grinding machine. Thus Alka engg. has obtain quotation for New Vertical surface grinder from supplier suitable to this component & had forwarded to KOEL for further clearance. Awaited for KOEL reply on this.

Defect-: Thrust cap width specified 29.81 to 29.84mm & observed o/s & u/s



INSPECTION METHOD IMPROOVED.:-- 1)Provided Digital Micrometer to grinder operator at work station 2) instruction given to operator to check the size at three points where thrust washer rest. 3) Also provided Special Dial type user friendly Gauge in order to get simplicity into inspection method.

Defect-: Thrust cap width specified 29.81 to 29.84mm & observed o/s & u/s

Digital Micrometer Spl. Dial Type GaugeAnalog Micrometer

PLANNED ACTION STATUS:- COMPLETED ON JUN 15 1st. WEEK



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Customer Name KOEL


What Happen ? LOP Cap Ø12 mm dowel hole depth observed plus


When did it happen? 25/07/2015Where it has been detected? KOELWho has detected it? KOEL Assembly

How it has been detected? During Fitment of Lub oil Pump

How many detected? 01 Nos.Recurrence No


Defect-: BRG Cap Ø12 mm dowel hole depth observed plus



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ROOT CAUSE ANALYSIS:- This operation we are doing manually on Conventional RDM. And due to negligence job passed to customer end . For inspection only plug gauge is available at work station to check the size. Depth gauge is not available.

ACTION TAKEN:-

We have provided Plug cum depth gauge at work station to ensure the diameter as well as depth of Ø 12 mm dowel hole.

Defect-: LOP Cap Ø12 mm dowel hole depth observed plus



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Customer Name KOEL


What Happen ? LOP Cap Ø12 mm dowel hole Centre distance Mismatch


When did it happen? 07/07/2015Where it has been detected? KOELWho has detected it? KOEL Assembly

How it has been detected? During Fitment of Lub oil Pump

How many detected? 02 Nos.Recurrence No


Defect-: BRG Cap Ø12 mm dowel hole Centre distance Mismatch



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ROOT CAUSE ANALYSIS:- We are performing this operation manually on conventional RDM. And this may be happened due to drilling jig plate not placed properly into location main Bore because operator has not cleaned the Jig plate & crankcase face

ACTION TAKEN:-

Earlier we had provided brush to clean the drilling Jig & Crankcase . Awareness increased of operator by the forum of standing meeting at work station.

Defect-: LOP Cap Ø12 mm dowel hole Centre distance Mismatch



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Thank you

rv3 koel quality issue- srf action... plan 14 08 15 a

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