CSB QUALITY PROBLEMS

Rework Hrs Sr. No. Date M/C No. Part No. Part Name Problem description Supplier's Name R/W done by Machine delay Actual Rework min min 0 0 15 0 0 0 0 0 15 15 Root causes analysis Total Rework min 0 0 15 15 15 Not required Not required Handling improper in house at ALIL Dist. 24.1 (+0.1 ) u/s by 1 mm./Operator mistake M10 & 10.2 are not concentric/Tapping not done w r t hole 10.2

1 2 3 5 6

04.07.2011 04.07.2011 04.07.2011 11.07.2011 11.07.2011

5123249 5123241 5123261 5123305 5123305 61242802-04 61242800-01

Wear Liner Beam for lifting sling Fibre glass guard Bracket, Frame Torque arm bracket, Al control Frame

Marks on ID Light Step observed Scratches found during assembly Bracket, frame --automation part fitment problem Load cell bracket fitment problem

Serview Technomech Omkar Mhalsakant Mhalsakant

Salavged Salavged Rework by Supplier Replaced ALIL

12.07.2011

5123370

61239760-80

Leakage

Srujan

ALIL

90

90

Welding pin holes

12.07.2011

5111416

61240424-01

Bracket Machined v-Belt pulley Plannet wheel

Fitment problem

Mhalsakant

ALIL

15

15

Dimn. 45 0.2 obs. o/s by 0.7/ slot milling setting not done properly. Light step obs. On Id/Power failure while boring.

9 10 11

13.07.2011 13.07.2011 13.07.2011

5123302 2.5 5123371

61232116-01

Fitment problem with hub Dents Main drive pulley & small end hub pulley alignment problem

Mhalsakant Hero Srujan

supplier

10

10 0

61239760-82

Frame 200

ALIL

60

60

To be investigated

12

13.07.2011

890008

61231946-89

Frame 360

Bowl fitment problem

Creative

supplier

480

480

Machining supplier changed. Doesnt have proper inspection tools.

13

15.07.11

5111416

61240289-80

Frame 280

Cover switch holes missmatched.

Creative

R/w done in hold time

10

10

Position of earthing screw was wrong.

14

15.07.2011

5123325

61242375-81

Frame, VFD

Electrical bracket fitment problem with frame--Large amount of gap obs betn Coupling & sensor. Vessel fitment problem with frame--one hole mismatched Top part leakage problem. back drive alignment problem vessel fitment problem with the frame

Srujan

ALIL

Under trial

15 16 17 16

15.07.2011 15.07.2011 15.07.2011 16.07.2011

5123282 890008 5123293 5123282

61211803-87-01 61241947-43 61240292-01 61211803-87-01

Collecting vessel Top part Motor plate Collecting vessel

Alok Dynaxcel Technomech Alok

ALIL ALIL ALIL ALIL

15 180 180 180

0 0 0 0

15 180 180 180

Vessel leg hole missmatch. Improper fitment of gasket & silicon by assembly person. No clearance for adjustment/alignment. Vessel leg hole missmatch.

18 19 20

18.07.11 18.07.11 20.07.11

5123309 5123275 5123310

61242138-82 61241942-83 61241942-58

Top part Frame 360 Frame 361

Nozzle fitment problem with cover Backdrive plate fitment problem funnel fitment problem with frame

Dynaxcel Bestall Bestall

ALIL ALIL ALIL

0 60 15

10 0 0

10 60 15

start threading problem. Frame CD u/s by 1 mm. Funnel Fitment CD o/s by 0.5 mm/ Error in drill jig Top part hinge thickness o/s by 0.5 mm /Operator mistake Not checked properly by gauge ( ms top part ) Wrong bracket used by assembly person

21

25.07.11

5123283

61211803-87-01

Collecting vessel

Top part touches to bowl. Dome shape shifted ( Gap uneven ) wrt radius of top part Sensor bracket & fitment problem

Alok

supplier

10

10

22 23 24 25 26 27 28

26.07.11 26.07.11 29.07.11 29.07.11 29.07.11 30.07.11 30.07.11

5111416 5123307 5123308 5123411 5123327 5123353 5123327

61240289-80

Frame 280

Srujan

ALIL

20

20

61240381-86 61239783-82 61232744-80 61241942-51 61211803-87-01

Centraflex coupling Top Part 280 Bracket, Painted Frame Collecting vessel

Threads were damaged. Top part damaged uneven casting surface Frame tapping not done & blastinfg on machined surfaces vessel fitment problem with the frame

Vulkan Srujan Arni-Mech

ALIL ALIL ALIL

0 60 10 180

0 0 0 0 0

0 60 10 180 30 27.66666667

Oblong hole drilled hence tapping not done properly To be investigate Fetling nopt done properly Operation missed Warpage obs.

Alok

30

Corrective actions taken

Status

Remarks

No action No action To be studied further 100% inspection at supplier end & awareness given to operator. Tapping will be done w r t 10.2 hole.

ok OK Pending ok ok

100% Leak test taken At higher level. Supplier should send the photos of leak test

pending

Awaireness given to operator. 100% inspection. Supplier to make a plug gauge for checking and send a photo to us.

ok

pending ok Pending Reject & scrap at ALIL Frame is of as per drg. 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 Guage will be ready for inspection till 25/07/11 at supplier end.

Informed to supplier to check frame 100% by special guage ( Mandrel )

pending

Special guage developent inprocess to check cover switch holes .

pending

Trials are going on. Jobs as per new dimensions are ordered.

pending

Will receive on 1/8/11

To be investigated Awaireness given to operator. To be decided To be investigated

pending ok pending pending Ok To be investigate by Development.

Threading corrected. To be decided. New Drill jig to be made by supplier Awaireness given to operator/Top part hinge thickness checked 100% at supplier end Informed to supplier to check 100% by gauge Use correct Part.

ok pending pending

Ok To be investigate New Drill jig to be made by supplier till ----

ok

ok ok ok Reject & send back to supplier on MRV Top part damaged inhouse

Blasting & rewok done Surface made even by griding. Informed to operator & inspector 100% check with checking fixture ( Base frame ) at supplier end before dispatch.

ok ok ok ok

CSB QUALITY PROBLEMS

Sr. No. Date M/C No. Part No. Part Name Problem description Supplier's Name Rework Hrs R/W done by Actual Rework Machine Total min delay min Rework min ALIL Supplier Acceptable 0 0 0 0 0 0 0 0 0 Root causes analysis Corrective actions taken

01.08.11 03.08.11 03.08.11

5123329 5123435 5123329

6120733538/61207330-23 61240289-80 61240010-80

v-Belt pulley & taper lock Frame 280 Base frame

Runout problem ( 1.2mm ) Eye bolt fitment problem ( Hole shifted ) Horizontal alignment problem

Imp. Creative Creative/Ry Ind.

Imported taper lock & local pulleys used. Tapping dist. Of M16 shifted by 10 -12 mm Horizontal alignment obs. Higher side

Informed to buyer supplier informed for gauge development to maintain dist. To avoid manual marking error. Scrapping operation added.

03.08.11

5122226

61240369

Plate Dam

Number not punched at bottom side of plate dam

Dynaxcel

Supplier

After assey. Radius Punching not seen. ( AS per Drg. Ok )

New drg. Given to supplier

04.08.11

5113350

61240796-81

Frame 450

Blasting done on cladding

Bestall

ALIL

120

120

SS blasting strips not used.

Awaireness given to blasting supplier to use ss strip plates.

04.08.11

5123340

..

ECB wrt motor plate Base frame

Back drive alignment problem

Assembly

ALIL

10

10

Paint & putty

Instructed to assembly operator to ensure cleaned machining surface before alignment. Instuction given to painting supplier ( Tricolour ) to improve material handeling.

04.08.11

5123329

61240010-80

Base frame was damaged at the base Leg )

Crative

ALIL

60

60

Improper handeling at Tricolour.

05.08.11

5123314

61230634-80

Frame 450

Frame baffle touches to bowl

Bestall

Supplier

180

180

Referance difference of machining & fabrication drawimg Improper bending of guard Missed by operator To be investigate As per drg. Ok

After machining calculated dist. To be maintained by supplier Informed to supplier for 100% inspection. Informed to supplier New lot sent by suppier & lot is ok

05.08.11 09.08.11 10.08.11 16.08.11

5111413 5123331 5123332 5123400

61242051-01 61235841-79 61167208-90 61204028-15

Guard Top part 937 O-ring Damper

Guard fitment problem with Frame Artival no. not punched on top part. O-ring broken while assembly. Height uneven

Serview

ALIL ALIL

10 5 10 0

0 0 0 0

10 5 10 0

Vako Imp.

17.08.11

5111353 5123317 ( 440 ) 5111353 5123476 5123339

61242127-80

Hub Large End

Level tube fitment problem with hub.

Tamboli Engg.

ALIL

20

20

Burr inside the bore Plate restrictin in drilling --Chances of drill brakage Threading start damage Operation missed ( Milling not done ) To be investigate

Inforrmed to supplier to to clean the burr properly & develop the gauge for inspection.

18.08.11 19.08.11 20.08.11 20.08.11

61243749-88 61241947 61242375-80 61207527-20

Frame 440 Top part Frame 200 VFD Tooth belt pulley

Drilling not done throught the length. Nozzle fitment problem Alignment problem Screw slips in tapping

Creative/Ry Ind. Dynaxcel Srujan Gateej ent.

Supplier Supplier Supplier ALIL

30 240 120 15

0 0 0 0

30 240 120 15

Informed to supplier to check threading by gauge 100% before dispatch Informed to supplier-to add check point in inspection report. Informed to supplier

22.08.11 22.08.11 23.08.11 24.08.11 25.08.11 27.08.11 27.08.11 27.08.11 27.08.11 30.08.11

5123339 5123382 5123317 ( 440 ) 5123360 5123390 5123318 ( 440 ) 5122218 5123386 5123346 5123335 61240421-00 6124391080/61243749-88 61241947 61245409-83 61243993-00 61243993-01 61241946-89 61230634-81 61211803-87-01

Gasket Hinge for cover Motor plate & frame Top Part Block Motor palte 450 Bearing housing Frame frame COLLECTING VESSEL NX418

Less gasket outside the top part slot Bracket cover fitment problem Gap observed between motor plate & frame & Top part screw fitment problem Block fitment problem Bearing housing fitment problem Jacking screw tapping not done for whole depth Back drive plate fitment problem/ M16 Tapping hole shifted Dowel pin depth problem Vessel plate to frame fitment problem

SD Chemicals Serview Creative Dynaxcel Technomech AKP AKP Bestall Bestall Alok Equip.

ALIL ALIL Supplier ALIL ALIL ALIL ALIL ALIL ALIL ALIL

10 5 120 30 60 60 10 240 0 30

0 0 0 0 0 0 0 0 0 0

10 5 120 30 60 60 10 240 0 30 23.0833333

Defective piece of gasket for 100 mm Wrong hole refferance taken Milling of motor plate resting area on frame was shifted wrt tapping hole Handling/welding/transportation warpage Milling Refferance shifted To be investigate Operation incomplete To be investigate acceptable Welding warpage

Informed to supplier Informed to supplier Informed to supplier to correct the milling refferance Baffle added New gauge to be develope for inspection of milling referance & threading.

Informed to supplier

Informed to supplier to check plate fitment with fixture ( Gauge ) 100%

Status

Remarks Trial taken & used another taper lock, Runout found ok..

ok Pending Pending

Ok

After 01 frame next frame will be received after As per Dgr. Plate dam is ok. We informed to supplier --Punch the article no. at bottom side

ok

Debited to supplier

ok

ok Informed to supplier to maintain calculated Dist. 321 between dowelling

ok

ok ok ok Ok stock to be checked & informed to supplier. As per drg. Damper height ok.

Pending.

New lot not received.

Pending. OK OK Pending Replaced Retapping done

OK OK OK OK Pending Pending OK Pending OK OK

Replaced Light grinding ( 0.5 - 1 mm ) Chamfer done on motor plate corner & problem solved.

All parts checked found ok

Informed to supplier to check CNC programm & inform

CSB QUALITY PROBLEMS

Sr. No. Date M/C No. Part No. Part Name Problem description Supplier's Name R/W done by Rework Hrs Actual Rework min Machine delay min Root causes analysis Total Rework min

03.09.11

5123406

61241947-62

Top Part 360

Light gap in rails welded with cover, resulting --silicon leakage & loose fitment of gasket Bolt fitment problem with damper--bolt head strikes with motor

Dynaxcel

ALIL

10

10

Welding warpage

02.09.11

5123243

61195636-58

Motor

ABB

ALIL

10

10

To be investicated Drilling not done throught the length./ Plate restrictin in drilling --Chances of drill brakage

05.09.11

5123243

61243749-33

Frame 440

Electrical wiring problem to Frame

Creative & RY

ALIL

60

60

05.09.11

5123407

61242248-01

Driver

Driver does not have slot

Micro-India

ALIL

Operatiom missed.

05.09.11

5123297

61243816-02

Flange with gutter

Fitment problem

Arni-mech.

ALIL

60

60

Stock with old revision

05.09.11

5123387 & 5111354

61242742-80

Centraflex coupling

Found burr inside the coupling

Vulkan

ALIL

10

10

Job not cleaned after machining.

06.09.11

5123387

61241993-80

Back Drive, Plate

Earthing screw broken

Technomech

ALIL

30

30

Quality of welded stud was not proper

07.09.11

5123520

61240424-01

Bracket machined

Fitment problem

Mhalsakant

ALIL

Paint inside the bore

08.09.11

5123243

61243749-33

Frame 440

Wear liner fitement problem

Creative & RY

ALIL

60

60

Warpage during welding of the blaocks

10 11 12 13 14 15 16

10.09.11 10.09.11 12.09.11 12.09.11 12.09.11 13.09.11 14.09.11

5123408 5127430 5111432 512346/5123388 5111432 5123455 5123455

61241958-42 61235390-01

Frame Motor plate O-ring

backdrive alignment problem Back drive alignment problem Fitment problem Fitment problem Back drive plate with frame fitment problem Incomplete reaming Bearing cover fitment problem with housing

Bestall Technomech Vako Ganesh Engg. Technomech / Bestall Creative & RY AKP

Supplier Alil

60 240

60 240 0

Dist. 201.00 found u/s by 2.5 mm. Motor plate thickness o/s by 1 mm / incomplete operation To be investicated Hinge hole dist. Found u/s Dowel pin jam in hole Incomplete opertion by operator Bearing cover ID U/s by 0.1

61242533-80 61235390-01 61240010-80 61232699-01

Hinge for cover Moter plate / frame Base frame Cover

ALIL Alil ALIL ALIL

10 240 30 20 0 0 0

10 240 30 20

18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 36 37 38 41 42 43 44 45

14.09.11 15.09.11 15.09.11 19.09.11 19.09.11 19.09.11 20.09.11 21.09.11 21.09.11 23.09.11 23.09.11 23.09.11 24.09.11 24.09.11 24.09.11 26.09.11 26.09.11 26.09.11 26.09.11 26.09.11 27.09.11 29.09.11 28.09.11 29.09.11 29.09.11

5123453 450 5123337 5123297 440 5123409 5123416 5123479 5123409 5123289 5123397 5123465 5123565 5123565 ( 200 ) 5111433 5123402 440 5123402 5123660 5123398 5111441 5123560 5123606 5123500 5123424 5123398 5123472 5123560

61239619-01 61235371/5372-80 61243749-44 61241942-58 61241942-79 61241947-44 61241942-58 61241993-80 61241946-89 61241942-81 61239831-01 61239783-82 61241947-41 61243751-96 61243759-65

Back Drive, Plate Guard Frame Frame 360 Frame 361 Top Part 360 Frame 360 Back Drive, Plate Frame 360 Frame 036 Inlet pipe support Top part 200 Top part 360 Frame 440 Top part 441 Flange for ECB

Back drive plate having uneven surface Guard fitment problem with the frame Solid funnel fitment problem back drive alignment problem At frame feet welding not done Top fitment problem /Top part baffle touches to bearing housing Solid funnel fitment problem back drive plate fitment problem Gutter fitment problem Main drive fitment problem to frame/ Pulley touches to frame net Inlet tube baracket fitment problem Key strikes the top part during back drive motor rotation Top part baffle touches to Bearing housing Seal ring fitment problem to frame Cover gutter fitment problem Flange for ECB fitment problem with the frame Seal ring damage during assembly Baffle & bowl having less gap Back drive plate fitment problem ( tapping ) Feeed tube strikes the inside bore of Conveyor. VLM drilling not on the frame Top part leakage problem. frame having blow hole /At inlet radius is uneven Nozzle fitment problem with the top part Electrical bracket fitment problem with the frame

Technomech Bharat Fabrication Creative & RY Bestall Bestall Dynaxcel Bestall Technomech Bestall Creative AKP Srujan Dynaxcel Creative Dynaxcel

ALIL ALIL ALIL Bestall Bestall Dynaxcel ALIL

10 20 30 240 30 15 15 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

10 20 30 240 30 15 15 0 0 30 20 30 15 45 45

Light excess material on plate/ raw material defect Undre investigation Proper tapping not done Dist. 201 obs. 199.5 ( U/s by 1.5 mm ). Operation missed. Welding shrinkage Proper tapping not done Wrong plate issued from store Acceptable Motor plate resting bar is u/s by 5 mm. Inlet pipe support dist. 19 obs. o/s ( excess machined wrt casting ) R20 found u/s. Warpage & bent obs. In welding. Undre investigation Undre investigation

ALIL Creative ALIL ALIL ALIL ALIL ALIL

0 30 20 30 15 45 45

61241946-89 61242754-81 61240289-81 61239831-01 61240289-81 61241947-41 61241946-89 61242132-74 61240289-81

Frame 360 Frame 361 Frame Inlet pipe support Frame 280 Top part 360 Frame Top part Frame 280

Creative Bestall Bestall AKP Srujan Dynaxcel Creative Dynaxcel Srujan

ALIL ALIL ALIL ALIL Supplier ALIL ALIL ALIL ALIL

0 10 0 20 0 30 30 0 10

0 0 0 0 0 0 0 0 0

0 10 0 20 0 30 30 0 10

Wrong supply from supplier req. -89 obs. 83 Referance difference of machining & fabrication drawing Retapping not done after painting. Inlet pipe support dist. 19 obs. o/s ( excess machined wrt casting ) Drawing revision changed & latest drawing not given to supplier. Welding warpage To be investicated Blasting cover paper on start of the thread. Frame CD o/s by 0.4 mm. / Drilliing tapping done by manual marking

46 47

30.09.11 30.09.11

5123426 5123456

61241972-01 61211803-87-01

Cover Vessel

bearing cover issued without tapping. Vessel req. M6 tapping but tapping done M4

Arni-mech. Alok ALOk

10 30

0 0

10 30 25.5

operation missed. Drawing not reffered while operation

Corrective actions taken

Status

Remarks

Inform to suppier to maintain spot welding & fusing distances correctly.

Ok

Rewokdone

Pending

grinding ( Rework done )

Pending

Inform to supplier to check 100 % before dispatch.

Ok

Replaced.

Reject & sent back to supplier

OK

Jobs 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 ) Instructed to supplier to chech bore after painting

Ok

Ok

Special checking gauge will be developed by CMA and used for in-process inspection. Target date - 16.09.2011 New gauge to be develop by supplier Informe to supplier

Pending

Pending ok pending

Rejected & sent back to supplier

As per drg. O-ring ok.

Tapping reference to be changed Instruction given to assembly person to apply lubricant while pin assembly. Communicated to supplier regarding reamer depth Informed to supplier.

Pending ok Ok Ok

Instructed to supplier to use proper raw material

ok Pending Gap uneven--Fitment ok Retapping done Rejected sent back to supplier Rework done Rework done

Istructed to supplier to check funnel tapping 100 % Machine calibration Informed for proper visual inspection. Inform to reduce shrinkage in welding by proper holding Istructed to supplier to check funnel tapping 100 % issue motor plate by conforming art. No.

Ok Ok Ok Ok OK OK OK

seen by Mahajan Sir Grinding r/w done Grinding r/w done

All bar corrected as per drawing. Pattern corrected Radius corrected wrt center ( check point added ) Inform to supplier to check 100 % before dispatch.

Ok Ok Ok Ok Pending Pending

OK After machining calculated dist. To be maintained by supplier Informed to supplier. Pattern corrected latest drawing given to supplier. Inform to reduce warpage in welding. OK OK OK OK OK Pending Instructed to clean the threading before assembly. Instructed to use gauge for drilling tapping & reduce manual error. Ok Pending

Used hold frame for assembly.

Grinding r/w done Inhouse rw done

Informed to supplier. Instructed to reffer drawings while performing operations

OK OK

Sr. No. 1 2 3 4 5 6

Date 07.10.11 08.10.11 08.10.11 08.10.11 10.10.11 11.10.11

M/C No. 5123496 5123417 5123515 5111443 5123458 5123496

Part No. 61237229-21 61242132-83 61241946-83 61242754-81 61241803-87-01 61242017-81 61207335-25/6120733319

Part Name Taper Lock Top part sticker Frame Frame 450 Vessel 353 Feed tube

12.10.11

5123459

Pulley/Taper lock

13.10.11

5123358

61243764-81

Upper casing

9 10 11 12 13 14 15 16 17 18 19 20

13.10.11 13.10.11 14.10.11 17.10.11 17.10.11 18..10.11 18.10.11 18.10.11 18.10.11 18.10.11 19.10.11 19.10.11

5123419 5111444 5123482 5123433 5123522 5123509 5123482 5111463 5123514 5123433 5123341 5123509

61242171-80

Level tube

61242132-83 61241942-61 61239619-01 61235841-80

Upper casing Frame Motor plate Upper casing

61241947-62 61242132-83

Cover Upper casing Coupling

61238026-02

Fibre glass guard

21 22 23 24 25 26 27 28

19.10.11 19.10.11 20.10.11 21.10.11 21.10.11 21.10.11 24.10.11 24.10.11

5111463 5123358 5123552 5123498 5123451 5123452 5123452 5123454

61241947-49 61243693-01

Upper casing Bearing Housing Frame

61236296-80

Guard

61211803-87-01

COLLECTING VESSEL NX418

CSB QUALITY PROBLEMS

Rework Hrs Problem description Key fitment problem with taper lock. Key fits jam in taper lock. V is missing in logo 'ALFALAVAL ' Bowl does not start in frame due to gutter ring. O-ring for flange with gutter & cover fitment problem. Bowl groove strikes with vessel baffle Inlet tube & O-ring fitment problem main drive pulley group----6120733525 SPZ V-belt pulley 250 having high runout value. Top part bolt fitment problem Supplier's Name Sankalp Engg. Dynaxcel Bestall Bestall Alok Serview R/W done by ALIL ALIL Supplier ALIL ALIL ALIL Actual Rework min 10 120 240 15 10 0

CMB

ALIL

15

Dynaxcel

Level tube fitment problem. Bearing housing for small end having blow holes. Bearing housing issued with blow hloes. Nozzle fitment problem with top part. Torque arm assembly fitment problem Back drive plate fitment problem Top part leakage Sensor & bracket fitment problem Top part blasting not done properly/ rust obs. Top part leakage Gearbox shaft to coupling fitment problem. Fibre glass guard rubber bush fitment problem.

Zeal Ent.

ALIL

15

AKP Dynaxcel Bestall Technomech Dynaxcel

ALIL Supplier ALIL Supplier Dynaxcel

0 15 30 30 10 10

Dynaxcel Dynaxcel Vulkan Onkar

ALIL ALIL Vulkan Supplier

60 10 15 15

Top part leakage Dowel pin tightning problem--During tightning, socket strikes with bearing housing. Junction box hole not on the frame Guard cutting not done properly Throught drilling not done for alignment holes. Vessel fitment problem with Frame & gasket found less. Bolt fitment problem between Vessel arm & Frame Vessel fitment problem with Frame.

Dynaxcel AKP

Supplier ALIL

30 30

Shakti-N Mack

ALIL 10

Alok Equip.

60

UALITY PROBLEMS
Rework Hrs Machine delay min 0 0 0 0 0 0 Total Rework min 10 120 240 15 10 0 High points obs. on taper of taper lock./Claning not proper Root causes analysis Taper conversion not proper sticker time --after pasting not taken before blasting/ 'V' removed in blasting. tap was broken in gutter radius & high points of welding on gutter radius. Blasting on machined radius area. Baffle extra bend obs. In handeling

15

Design error in top part ( Red DN received )

15 0

Rust inside the tapping.

0 240 0 0 0 10 240 360 0 0

0 255 30 30 10 20 300 370 15 15

Acceptable Threading damage in handeling Manual marking --referance not taken properly ( From machining ). Tapping holes not drilled in line. CD 610 mm obs. u/s by 0.2 Pin hole in welding Bracket bend obs. Grinding burr striked on this top part, while reworking another top part Welding crack obs. zink plated alu-passivation layer inside the bore. Putty & paint inside he paint.

360 0

390 30 0 0

Welding crack obs.

10 0 0

60 32.66666667

Corrective actions taken No conversion or conversion as per drawing. Stcker pasting time to be maintained & after blasting sticker to be inspected. M4 screw fitted with the frame ( In gutter radiu ), will receive from next lot. Machined area( radius ) to be protected from blasting. Informed to supplier for proper handeling Under investigation Before assely clean taper lock & pulley tapered area propely.

Status OK OK Ok Ok Ok Pending

Remarks Taper lock changed. R/w at ALIL by supplier.

manualy polished.

AS per drawing both part are OK. Taper lock replaced.

oK

Design changed.

oK

Informed to supplier

oK OK

Cleaned by air. MRV

Acceptable Informed to supplier for proper handeling Gauge to be developed Center drill to be used from next batch. instructed to welder for proper welding. Instructed for proper clamping in welding. Proper covering to be done while rework.. Awaireness given to welder plain plug gauge developed for bore checking. Gauge developed, OK Pending Ok Ok OK OK Pending OK Ok Rework done for all stock Debited to supplier Rework done Retapping done Rewok done Plate changed, fitment ok.

Awaireness given to welder

Pending

Debited to supplier dynaxcel

Sr. No.

Date

M/C No.

Part No.

Part Name

01.11.11

5123466

61211803-87-01

Collecting vessel

02.11.11

5123454 ( 353 )

61240011-83

Sub Frame

02.11.11

5123467

61211803-87-02

Collecting vessel

02.11.11

5123466

00533019-02-01

Bearing holder

02.11.11

5123449

61241993-80

Motor plate

02.11.11

5123467

61240010-80

Base Frame

03.11.11

5123391 ( 440 )

61242802-08

Bracket for al control.

03.11.11

5123446

61207330-17

Taper lock

04.11.11

5123485

61235841-80

Top part PANX

10

04.11.11

5123461

61211803-87-01

Collecting vessel

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

15

08.11.11

5123462

61211803-87-01

Collecting vessel

16

08.11.11

5123461

61240321-83

Centraflex coupling

17

08.11.11

5123449

61242132-83

Top part

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

61241972-01

Cover for bearing housing

24

14.11.11

5123486

6123584180/61239398-82

Cover & 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

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 )

61240010-80

Frame 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

41

22.11.11

5123405

61243759-65

Top part

42 43 44

22.11.11 23.11.11 24.11.11 3.5 DD Gearbox. 5123405 ( 440 )

61231942-51 61240885-01 61244218-80

Frame Sunwheel shaft 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.

Rework Hrs Problem description Supplier's Name R/W done by Actual Rework min Machine delay min

Vessel fitment problem with the frame

Alok

Supplier

120

Earthing nut missed.

Creative

ALIL

10

Vessel fitment problem with the frame

Alok

Supplier

120

Bearing holder fitmrnt problem with wear bush.

Mhalsakant

Supplier

Back drive plate CD does not match with the frame

Technomech

ALIL

Legs of Base frame was damaged.

Creative

Supplier

30

Bracket for torque arm having high points in it.

Sanjivani

ALIL

15

Taper lock used without Blackwadising

Kvissgaard

Top part bolt fitment problem with frame

Dynaxcel

Supplier

120

Vessel fitment problem with the frame

Alok

Supplier

120

Loose fitment of bearing & bearing housing.

AKP

..

Bearing rotates freely on shaft

Mhalsakant

ALIL

10

Main bearing pulley & bearing housing rubbing problem.

30

Main drive pulley --Balancing weight falling problem.

CMB

ALIL

30

Vessel & sub frame fitment problem

ALOK

Supplier

120

Pin broken

Kvissgaard

10

Top part hole not machining

Dynaxcel

ALIL

120

Drilling not done throughout at Gland location.

Creative

Supplier

20

Wear screen fitment problem

Creative

Supplier

240

Electrical plate fitment problem.

ALIL

Vessel fitment problem with the frame

Alok

ALIL

120

Bearing rotates freely in housing.

SKF

Blow holes to Cover for Bearing housing

Arni-Mech

10

Gutter not maching.

ALIL

ALIL

Rust spots on cover ( gear side )

Dynaxcel

ALIL

Top part hole not machining

Dynaxcel

ALIL

90

Top part touches to Bearing housing.

Dynaxcel

ALIL

15

Cutting not done properly.

Shakti-N-Mach

Supplier

10

30

Top part hole not machining

Dynaxcel

ALIL

60

M8 x 12 tapping strip not welded

Creative

Supplier

90

During RA mounting in a frame, bearing housing strikes with the frame.

Creative

ALIL

30

Funnel fitment problem with the frame

Serview

Serview

240

240

Back drive alignment problem.

Baldor.

ALIL

Guard fitment problem--Making noise in testing.

Serview

ALIL

10

Washer fitment problem with actuator arm.

Ganesh Engg.

Supplier

10

RA does not rotate in frame ( Fitted )

Creative

ALIL

60

Motor plate fitment problem with motor.

Technomech

Supplier

45

Guard without end plate proper laser cutting not done.

Shakti-N-Mach

ALIL

15

Hinge pin fitment problem.

Dynaxcel

ALIL

10

10

Top hole not matching.

Dynaxcel

Assembly.

15

Top hole not matching.

Dynaxcel

Assembly.

165

Frame CD 490 obs. 500 mm Sun wheel shaft machined ,PCD problem,Not maching. Gap obs. Between motor plate & Frame.

creative Grindel. Technomech

Supplier ALIL ALIL

120 10 0

0 0 0

Back drive alignment problem.

Torspec

ALIL

180

Wear screen fitment problem.

Creative

ALIL

30

Cover rusty.

Prashtech.

10

Waviness in gasket rail.

Dynaxcel

ALIL

10

O-ring cuts during assembly.

Vako

ALIL

30

Rework Hrs Total Rework min Root causes analysis Corrective actions taken Status

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 Awareness given to weider & check point added in PDIR. 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.

OK

120

Base weared out of checking fixture

OK

As per drg ok.

used for another machine

OK

Wrong motor plate issued

OK

Ok

30

Handeling 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

Ok as per supplier standard.

Inform to buyer to purchase from CMB or Local.

OK

120

Bow / 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

1)Fixture R/W done on 15-11-11 . 2) 100% inspection by feeler gauge for gap between base of vessel & frame assembly Base weared out of checking fixture. at Alok. 3) To avoid chances of resting lug warpage after glass blasting in ALIL Alok will supply vessel with glass blasting

OK

Ok as per drg.

OK

OK

10

Shaft is ok as per drg.

OK

Ok

30

To be investigate

Ok

30

Screw which holds balance weight breaks down

Informed to supplier

Pending -wating for next ok lot

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

Pin assembled with coupling by special Informed to supplier to despatch --Loose locktite parts of coupling. New gauge to be developed. Gauge design & manufacturing discussion will be between dynaxcel & ALIL on 16.12.11.

OK

120

Bow / Welding warpage observed & not checked properly.

Pending

20

Operator mistake & not checked properly.

Guage developed for checking.

Ok

240

Welding fixture not used properly & checking fixture not available.

1) Proper use of welding fixture & checking fixture developed on 10/12/11

OK

BOM error

Special palte made for subfarmae

OK

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

Acceptable

OK

10

Casting defect

Informed for 100% inspection for blow holes.

OK

Proper alignment not done.

Awareness given to assembly person..

OK

Improper cleaning after acid cleaning

Soap water cleaning added after acid cleaning New gauge to be developed. Gauge design & manufacturing discussion will be between dynaxcel & ALIL on 16.12.11. Check 100% on fixture both side 1 mm gap maintained.

OK

90

Bow / Welding warpage observed & not checked properly.

Pending

15

Welding warpage

OK

40

Improper laser cutting.

Instructed to supplier for proper laser cutting. New gauge to be developed. Gauge design & manufacturing discussion will be between dynaxcel & ALIL on 16.12.11. Awareness given to worker & point added in checklist.

OK

60

Bow / Welding warpage observed & not checked properly.

Pending

90

Negligence to work

Pending

30

To be investigate

Pending

480

Dimn. 13.00 obs. 5-16 mm of Funnel

Check point added.

OK

For alignment hole clearance not sufficient

CR to be raise

Pending.

10

Improper assembly

Awareness given to assembly person..

OK

ID Of washer U/S by 0.2 mm. Machining supplier changed. Frame fabricated in Creative & machined in bestall. Locating ID u/s by 0.5-0.6. Error in checking instruments.

Gauge developed for checking ID. 100 % check for UV frame by special mandrel. New mandrel will develop at bestall also & point added in Bestall QIT meeting. caliberation done & error removed.

OK

60

OK

45

OK

15

Improper laser cutting.

Instructed to supplier for proper laser cutting.

OK

20

Hinge hole dia. u/s

Gauge developed for hole Diameter. New gauge to be developed. Gauge design & manufacturing discussion will be between dynaxcel & ALIL on 16.12.11.

OK

15

Bow / Welding warpage observed & not checked properly.

Pending

165

Bow / Welding warpage observed & not checked properly.

New gauge to be developed. Gauge design & manufacturing discussion will be between dynaxcel & ALIL on 16.12.11. fixture to be developed.

Pending

120 10 0

manual marking done ( Imported item ) Welding warpage in Motor plate.

Pending OK

Flatness added on drawing & given to supplier. Informed to supplier & supplier agreed to maiantain this disd. Lower side 1) Proper use of welding fixture & checking fixture developed on 10/12/11 Rust removed.

OK

180

Dist. 132.00 ( -0.2 ) obs. 132.194 Welding fixture not used properly & checking fixture not available. Old batch job Handeling damage in specific area of rail. To be investigate

OK

30

OK

10

OK

10

Awaireness given to supplier.

OK

30 46.1666667

Pending

Remarks

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 will buy new blasting maching & install from Feb-12

As per drg. Bearing holder ok.

Motor plate replaced.

Acceptable

Fixture rework done on 15/11/11. Alok will buy new blasting maching & install from Feb-12

Parts checked OK as per drg.

Fixture rework done on 15/11/11. Alok will buy new blasting maching & install from Feb-12

Old stock

Action completed & waiting for Next lot

Action completed

Special plate

Fixture rework done on 15/11/11. Alok will buy new blasting maching & install from Feb-12

As per drawing both parts ok

Rejected & sent back.

Raw material is ok

Rework done.

Rework done

Action completed & waiting for Next lot

Rework done

Rework done by Suppiler.

Rework done

Target Date 17/12/11 MRV taken

Action completed

Sr. No.

Date

M/C No.

Part No.

Part Name

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

05.12.11

5123493

61211803-87-01

Collecting vessel

03.12.11

5123493

61240010-80

Frame

5123641

61241947-50

Cover

10.12.11

5123592

61211803-87-01

Collecting vessel

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

08.12.11

5123591

61211803-87-01

Collecting vessel

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

5123594

61211803-87-01

Collecting vessel

17.12.11

5123579

61243759-44

Cover

17.12.11

5111451

61207537-01

Counter shaft

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

61241947-50 17.12.11 17.12.11 5123594 61240010-80

Cover

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

61242004-01

Shaft for conveyor bearing. Weal Liner

31.12.11

5123427

61244138-01

29.12.11

5123646

61243759-53

Upper casing

27.12.11 31.12.11

5123664 5123427

61204028-19 61242533-81

Vib. Damper Hinge for cover

29.12.11 28.12.11

5123530 Gear box 8 Knm

61207537-01

Shaft Sunwheel Shaft

Rework Hrs Problem description Supplier's Name R/W done by Actual Machine Rework delay min min 60 0

Blasting not done from one side.

Srujan

ALIL

Fitment problem with pulley.

CMB

ALIL

Rubber bush fitment problem.

Onkar Udyog

ALIL

15

Top part holes not matching.

Dynaxcel

ALIL

180

Small spatters found on the frame

Bestall

ALIL

15

Dents.

ALIL

10

Uneven surface area.

AKP

ALIL

M12x25 Tapping problem

Ganesh Engg.

ALIL

Wear liner fitment problem.

Alok

ALIL

10

Water leakage from funnel

Serview & Bestall

ALIL

60

Blow holes on leg/resting area.

Alok

ALIL

15

Frame alignment problem.

Creative

ALIL

Top part holes not matching.

Dynaxcel

ALIL

15

Vessel cover touches to bowl

Alok

ALIL

60

Frame having uneven surface of foot section.

Bestall

Supplier

15

Reaming not done for base frame.

Creative

ALIL

10

Adapter fitment problem to hub, Holes not matching.

Shree Engg.

Fiunnel; fitment problem.

Serview

Supplier

15

Guard fitment problem with the Frame.

Bestall

ALIL

10

Vessel cover touches to bowl.

Alok

ALIL

60

Gutter ring fitment problem with the frame.

Bestall

supplier

Back drive alignment problem.

Creative

ALIL

180

Earthining screw fitment problem.

Creative

ALIL

10

Vessel to frame hole mismatch.

Alok

ALIL

10

Top part leakage.

Dynaxcel

ALIL

Countershaft plate fitmrnt problem.

Mhalsakant

ALIL

Tooth belt pulley fitment poblem.

Gateej Ent.

10

For base frame blow hole found on M16 tapping./ Counter drill shifted.

Creative

Supplier

10

Top part holes not matchining.

Dynaxcel

ALIL

15

Top part fitment problem---Baffle touches to bearing hgs. wrong motor plate issued on article number 61244160-80.

Dynaxcel

Supplier

30

Technomech

Supplier

20

360 top part--pin fitment problem

Dynaxcel

ALIL

10

Bottom surface of base frame for 4 leg having uneven surface area.

Creative

Supplier

30

Top part holes not matchining.

Dynaxcel

ALIL

90

Cross tapping to motor palte.

Technomech

ALIL

30

Counter shaft having circlip fitment problem.

Imported.

ALIL

10

Top part fitment problem with the frame

Dynaxcel

ALIL

60

Main drive guard hole shift

Serview

ALIL

In counter hole found welding.

Shree Engg.

ALIL

15

wear screen fitment problem with the frame

Serview

ALIL

10

Top part pin fitment problem. Back drive alignment problem after bolt tightining. Alignment varies upto 1 mm. Hinge for cover fitment problem with the top part. Shaft fitment problem with the pulley. Sunwheel having hign dents.

Dynaxcel

ALIL

10

Imported. Ganesh Engg.

ALIL ALIL

15 5

0 0

Mhalsakant Imported.

ALIL ALIL

0 5

0 0

Rework Hrs Total Rework min 60 Root causes analysis Corrective actions taken

Operation missed./operator not trained.

Training & awareness given to operator

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.

Excess grinding.

Pattern corrected.

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.

Ok as per drawing.

Ok

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.

10

Reamer not passed through the hole, Light step obs. At the end of hole.

Instruction given to operator.

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.

Ok as per drawing.

OK Trial to be taken for alignment ( Motor fitment holes to be checked on machine at supplier ). special caps to be develop for threading. 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. OK

180

Not sufficient clearance for adjustment/Alignment ( Baldor Motor ).

10

Threading start damaged.

10

Welding warpage.

No leakage

AS per drawing shaft OD ok.

Ok

10

ID 62.00 o/s by 0.015mm

10

Power failure while machining./Counter drill shifted Bow / Welding warpage observed & not checked properly.

Corrected as per drawing New gauge to be developed. Gauge design & manufacturing discussion will be between dynaxcel & ALIL Instructed for 100% check for baffle in ---right angle

15

30

Baffle bend obs. Wrong punchining done on motor plate & Physically motor was 61243910-80, punchining done as 61244160-80. Diameter found to lower side & burr obs.

20

Check point added in PDIR

10

New pin given to supplier for checking.

30

Handeling damage in blasting or painting .

Handeling process improved & higher side thickness channel to be used. New gauge to be developed. Gauge design & manufacturing discussion will be between dynaxcel & ALIL Tapping required to done on machine.

90

Bow / Welding warpage observed & not checked properly.

30

Manual tapping done.

10

Excess deformed.

Stock checked. New gauge to be developed. Gauge design & manufacturing discussion will be between dynaxcel & ALIL All stokk checked.

60

Hinge not in right angle

Problem in screw ( Not in guard )--Screw start damaged.

15

Blow hole reworked

Check point added in PDIR for heatmark & spatters. Check point added for twist in PDIR.

10

Wear screen twist.

10

Diameter found to lower side & burr obs.

New pin given to supplier for checking.

15 5

Damper problem/Trial to be taken As per drawing part ok.

Ok Refferance change drawing given to supplier. Ok All stokk checked.

0 5

Part ok as per drawing. Handling Damage

0 0 18.96667

Status

Remarks

Resolution method

Project Manager

OK

Inhouse blasting done.

Just do it

OK

Reassembled & found ok.

Just do it

OK

DMAIC Express

Nilesh Dubal

Ok

Two 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

Pending

Leakage from only one screw.

OK

Just do it

Ok

Accepted.

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.

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 Rejected & sent back to supplier.

Ok

Ok

Rework done

Ok OK

As per drawing pwrt ok. For M8 tapping hole rework done

OK OK Rework done

Assembly R/w hrs. due to receipt ( Supplier ) qualit Month Jul-11 Aug-11 Sep-11 Oct-11 Nov-11

50 45 40 35 30 25 20 15 10 5 0 Jul-11

Corrective action No action, Someone else to handle or referring to "further investigation". "Talked to", Informed or refering to ongoing project. New or changed procedure , verified by responsible managerand/or test. New or changed procedure is communicated, control plan or POKA YOKE / fail safe

Assembly R/w hrs. due to receipt ( Supplier ) quality parts. Hours. 27.6 23 25.5 32.6 46

R/w due to supplier quality parts

Aug-11

Sep-11

Oct-11

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 documented process. 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.

Supplierwise total r/w line & total r/w Hrs. for Nov.11 Supplier Name Creative comb. Dynaxcel Alok Equip. Serview Ent. Torspec Shakt-N-mach Technomech CMB Vako Sanjivani cast. Kvissgaard Prashtech Grindel Arni-Mech No. of r/w lines 9 10 5 2 1 2 3 1 1 1 2 1 1 1

Hours.

12

Nov-11

10

Rating 0 1 2 3 4

General Hit rate 0 1

total r/w Hrs. for Nov.11 Total r/w time (hrs.) 10.5 10.25 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.)

CSB QUALITY PROBLEMS

Sr. No. Category of operation mistake Category of inspection problem Rework Hrs. R/W done by Actual Rework min Machine Total delay Rework min min Root Cause

Date

Machine No

Supplier name

Part Name & No.

Problem Description

Problem Photos

04.07.13

5124820

Creative

Frame 61243749-23

Frame baffle touches to bowl

Machning

Manual

Supplier

360

360

Manual Checking Method. Fixture not available.

19.07.13

5124940

Creative/RY IND.

Frame 61245358-83

RA locked in Frame

Machning

Manual

Supplier

300

300

Fixture not available

Mins Hours

600 10

Immediate Actions

Corrective & Preventive Action Plan

Responsibility

Target Date

Production Production Operation Operation standard standard after ( before Complitation date )

Inspection standard before

Inspection standard after ( Complitation date )

Improvement Photos if any ( Complitation date )

Debit No.

Rework done

Fixture to be use

Creative

15.7.2013

C:\Documents and Settings\Administra

C:\Documents and Settings\Administra

C:\Documents and Settings\Administra

C:\Documents and Settings\Administra

Development Frame-Rework done

Fixture to be use

R.Y. industries

24.07.2013

C:\Documents and Settings\Administra

C:\Documents and Settings\Administra

C:\Documents and Settings\Administra

C:\Documents and Settings\Administra