rv3 koel quality issue- srf action... plan 14 08 15 a
TRANSCRIPT
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
1
ACTION PLAN FOR RECENT QUALITY ISSUE OBSERVED AT KOEL KAGAL IN
MONTH OF JULY 2015.
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
2
Action plan & effectiveness KOEL – Crank Case
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
3
DefectProblem – Sand wash/inclusion at drag side body & oil gallery.
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
4
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.
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
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
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
6
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.
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
7
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.
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
8
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
7
Total rejection %
Series1
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
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 %
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
10
Part Name: RV3 Crank-CasePart No :- 39.185.01.0.00
CUSTOMER REPORTED PROBLEM -:
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
11
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
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
12
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
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
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
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
14
Customer Name KOEL
Product Name & Part No. RV3 Crank-Case 39.185.01.0.00
What Happen ? LOP Cap Ø12 mm dowel hole depth observed plus
Why it is a Problem? Pl. refer next slide
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
Identify The Problem
Defect-: BRG Cap Ø12 mm dowel hole depth observed plus
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
15
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
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
16
Customer Name KOEL
Product Name & Part No. RV3 Crank-Case 39.185.01.0.00
What Happen ? LOP Cap Ø12 mm dowel hole Centre distance Mismatch
Why it is a Problem? Pl. refer next slide
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
Identify The Problem
Defect-: BRG Cap Ø12 mm dowel hole Centre distance Mismatch
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
17
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
Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
18
Thank you