Sr. No.

Category Supplier Part Name Problem details

BLOW HOLE
( mating face, groove area)

1 ADC Part Minerva B12D ADAPTOR COLD SHUT,SHRINKAGE, AIR LEAK

CASTING DAMAGE

P92 HSG-C CRACK AT BEARING BORE

2 FC PART Aditya Industries

2 FC PART Aditya Industries
PG HSG VISUAL CASTING DEFECTS

1.B.H
(gas trap below pipe pad)
P92 HSG-C 2.Hard(Chilling effect)
3.Air leak
4.Swelling at bolt boss

1.Flange pipe length undersize &

Varm Press Finish Part 4J Strainer oversize
2.Double net in assly

1.Tapping Spoil
Machineall Finish Part E494 Bracket 2.Dowel hole oversize
 Root Cause Improvements

Slag / impurity in furnace removing 1. slag removing process improved and its frequency increased to
process not proper avoid mixing of impurities while pouring of molten metal.

1.Die temperature not maintained 1. frequency increased for checking of Die temp by digital temp
as per required specification measuring instrument.
2.Die coating/lubricant spraying 2. Die coating(dielubex-400), and spraying of flux lubricant
process not followed properly. (unicote fl-15) after every shot improved.

1.Improper handling of hot ejected 1. For collection of hot ejected casting, step arrangement
casting implement, instead of direct through of parts in pallet.

1.Operator awareness increased by display of Quality alarm &

training for knock out operators.
Wrong Knock out / de-gating
practice of operator 2.For detection visual inspection strengthen & suspected parts
are tested by DP test.
 1.Awareness Training given to fettling operator.
Less awareness to fettling operator 2.OK samples provide at fettling station for comparison
3.Visual inspection standards display with OK/NG photographs

1.for improve finishing and sand properties charcoal percentage

1.low mould hardness
2.core gas entrap
3.improper inoculant mixture
4.sand properties not ok.
increased
2.barium typed inoculation improved and increased to eliminate
Hard (chilling issue).
3.air venting started to eliminate gas trap issue below pipe pad
(inside pipe).
4.mould hardness checked on different locations to track mould
hardness variation.

1.For flange pipe length variation, stopper introdeuces during

stopper arrangement not present in pipe pressing in main strainer body
strainer assembly.(manual pressing) 2.Firewall Inspection Activity started to detect defects visually.
3.Before assembly, process of child part verification introduces.

1.Machining Feed during tapping monitored and followed as per

1.Tapping tool holder run out not
confirm before every shift
2.air cleaning after driiling/tapping
not effective.
defined programmed.
2.Tap holder run out not checked before start of operation.
3.Air cleaning done after every drilling cycle to remove/clean any
burr in drilled hole.
 Evidence/Photo

slag

DIE TEMP DIE COAT

step 2 step 1

BEFORE

AFTER
visual inspection standard display board with master
sample

Arrangement done to escape core gases

stopper for control pressing length

Run out checking of Tap Air cleaning after drilling

holder cycle
 Status

MINERVA_REJ% TREND_2018-19
30 28.47
25
20
15 13.78 12.45
9.33 8.31
10 5.39 6.08
3.76
5
6.73
0