Process Audit observation for Processes Mix up test, Colour coding. SWIL Plant 2 - 14.03.

3030

Process
No. Process Not conformances. Corrective action Target date Resp. Remarks
number
System correction
1. Radioactive material verified at gate . Two different formats
1
are found. STR/MAT/02 DT. 05.03.2020. No. revision number .

System correction
2 2. Old format 08 09.2017 -. No format number - store
10 Scrap charging Need to address in the system and in Work
3. For Nickel plates there is no evidence for verification of ROH instruction for approval of RM
3 Things gone wrong
and reports.

Store all the loose plates bits and regular

4. RM Storage ; Nickel plate loose material are stored different nickel plates in one identified area
4
area without any identification and traceability.

Initial chemistry specn is changed for carbon. Not followed as

5 per technology sheet. Carbon to be corrected. Technology sheet
SWIL/TS/SMS/GEN/100

Different SMS process technology sheet is evidenced and process Things gone wrong .
6 is carried out as per the modified one . This modified one is Need detail of what are
Melting in differs for all the SMS processes and not as per Need to address in the new Technology sheet
20 all the corrective action
Electrical furnace SWIL/TS/SMS/GEN/100 dt. 22.11.2017. with all correction
introduced against new
process
Tramp elements addition are not as per the technical sheet and
certain addition like spar, calcium lime and call dolerite are not
7 address in the technical sheet.

The total melt composition is not as per the technical sheet.

8

9 30 Rearcing in LRF Chemical composition adjustment is not as per the tech sheet to Need to address in the new Technology sheet Things gone wrong
modified as per the new tech sheet. with all correction

10 40A VOD This process is not addressed in the technical sheet Introduce in Tech sheet

11 40 VD In VD old document are used and two different documents are Need system correction .
available like PRD/05 AND PRD /06

Need correction in Tech sheet.

12 Boron addition is not addressed in the technical sheet. Things gone wrong
Refining at LRF &
50 Need correction in CP or Tech sheet as per the
addition of alloys
Nickel taping specification differs between control plan and tech control plan
13 sheet. I.e. control plan specify : 30 - 33.50 % and tech sheet:
30 +/- 0.20 %.
14 Teeming and feeding time per plate defined as special Need to address in CP the statistical method
characteristic . NO statistical process control details evidenced. or remove the Semi cc.
Pit preparation
60 and Electrode
casting Electrode(ingot ) size mentioned as dia 350 / sq 350 . Where as
the actual electrode is 350 mm dia and 8 nos as 13 x 15 ingots. Need correction in CP or Tech sheet as per the
15 Things gone wrong
Difference observed. control plan

Electrode carried out as per SOP and recorded. Format number actual and
16 70 Need system correction .
conditioning control plan to be verified.

ESR log sheet , and process sheet and PLC control data are
17 80
verified.

Type of slag and melt rate are marked as semi critical

18 Need to address in CP the statistical method
characteristics. Where is there is no reference for statistical and or remove the Semi cc.
Remit at ESR monitoring.
Statistical data to be reviewed for next 10
Need verification process results for inclusion level , heat for grain size , inclusion , homogeneity
19 homogeneity of grain size, complete solidification and surface for repeatability.
smoothness before and after ESR.

Work instruction to be modified as per the

Work instruction and heat treatment are under trials . Hence new process flow in hot forging to
20 work instruction to be made as per the process flow followed in intermediate size as referred in the Non
hot forging intermediate size. conformance.

Approval column with ok or not ok to be

Forge shop log F/FS/02/-Rev 08/09/2019 difference observed. addressed in the report.
21
Decision making is not evidenced.
DP test carried out which is not addressed in control plan. To be added in the control plan
22 Hot forging to
90
intermediate size
Specified : SMS - 240 MM electrode - Forging. Work instruction to be modified as per the Process changed as This is one of the major
new process flow in hot forging to per NCR in Process process change to
Modified: SMS - 350 mm electrode - Reheating ( step heating intermediate size as referred in the Non achieve the desired
- 500 - 1100 deg c ) -F forge to 255 mm dia (with multiple conformance. results in Nireva 30 15.
heating ) - Stress relieve at 650 deg C for 16 hours. - ESR - Forge Hence marked as TGW
23 to 150 x 150 - stress relieve - DP to be carried out.

Any inspection report required for compliance

24 100 A Transfer to CFD Nil

(Plant 1)
 Process Audit observation for Processes Mix up test, Colour coding. SWIL Plant 2 - 14.03.3030

Process
No. Process Not conformances. Corrective action Target date Resp. Remarks
number

Conditioning of Forged Nil

1 110A Compliance.
Billets (semis)

2 120A Charging of Semis Process compliance Nil

This process is marked as semi critical characteristics Either introduce statistical data monitoring for
3 Nirova 30-15 heat treatment requirement are not addressed in the work process or product parameters or remove
Heating of semis for hot instruction F/RM/PRD/06 the semi cc
130A
rolling

4 Temperature as per control plan is 1130 - 1150 deg C , where as the Need correction in CP and WI
process temperature is 1120 Dec. Actual is 1115 deg C.

5 Format F/RM/PRD /06 and the register format number is different. Need system correction
Cogging of Billets )100
140
mm RCS) Things gone wrong.
ingot size is referred in control plan as 140 mm where as actual size is 70
6 Need system correction
mm

Heat tally form F/SMS/PRD/03. Old format SWIL/F/GEN/TF/TF/04 /03 .

7 100B Transfer of Billet of CFD Need system correction
Current format to be verified.

End Discards & stock

8 150 compliance.
Length cutting

conditioning of Rolled
9 110B compliance observed . But no recording of results evidenced Need system correction
billets

UT testing carried out . Two report generated . A linkage could be made

between the two reports.
NDT Inspection of Billets
10 - Dye Penetrant Testing Need system correction.
(surface )

160
DP test carried out . WI to be corrected.
NDT Inspection of Billets Regarding UT test in work instruction WI/QA/NDT/14 , In material details
11 - UT machine internal for testing , Nirova grade is not addressed
crack.

Nil
12 170 Lime coating No issue.

13 120 B Charging of Rolled Billets 100 RCS and compliance Nil

 TGW: During pre launch met
issue /hardness issue above
14 130 B Billet Reheating for bar ingot size is referred in control plan as 140 mm where as actual size is 70 Need system correction in CP , Tech sheet and 1100 deg.
rolling mm WI.

Final rolling to round Zyglo carried out as per control plan and recorded in record Need system correction in CP , Tech sheet and
15 180
bars of planned size SWIL/F/RM/ZT08/00 but the same is not addressed in control plan WI.

End cutting and fix

16 190 carried out and compliance. Control specified not recorded . Why Introduction of recording system .
length cutting bars

Transfer of bars to HT
17 100C Heat wise and grade wise identified.
shop

Control plan specify both air cool and quench. But any one process to be
followed. Need correction in control plan.
18 Need correction in CP and WI and system. Things gone wrong

Solution treatment annealing is 930- 1030 deg C . Actual is 960 -1120 deg
C . Difference observed.
19 To be corrected in system and CP, WI Things gone wrong
Solution annealing of
200
bars (optional )
Solution annealing process is marked as semi critical characteristics , but
there is no statistical requirement are specified for monitoring and
recording of either process or product parameters. Either introduce statistical data monitoring for
20 process or product parameters or remove
the semi cc

Need correction in system also it is critical to

There is no record available in plant 1. This process is referred in plant 1
21 210 Quality Testing attach the report on all the requirements of Things gone wrong
but not carried out
process 210.

22 All the characteristics are critical and no report observed.

Sampling requirement document number is not referred in the control

23 Need system correction.
plan.

Transfer to Bright Bar

24 100 D Heat wise and grade wise identifeid. Control plan referred as no record. Need system correction.
shop (Plant -II)
 Process Audit observation for Processes Mix up test, Colour coding. SWIL Plant 2 - 14.03.3030

Process
No. number Process Not conformances. Corrective action Target date Resp. Remarks

Need system correction in control plan , SOP

There is no inspection carried out In the process. But control plan etc.
1 220A Multi roller straightening specified that check once at the time set up . What to be checked
and why no record.

Rest plate thickness - how it will be selected for thickness which

is not addressed in WI Verification method to be addressed in the
2 SOP.
Degree angle plate calibration and also readability of marking is
220B Two roller straightening very poor .
since angle setting parameters is critical the
3 angle plate to be corrected with clear
readability and calibration by internal.

4 230 Peeling compliance observed. Nil

Rest plate thickness - how it will be selected for thickness which

is not addressed in WI Verification method to be addressed in the
5 220 C SOP.

Degree angle plate calibration and also readability of marking is

Two roller straightening very poor .
since angle setting parameters is critical the
6 angle plate to be corrected with clear
readability and calibration by internal.

Feed rate different scale followed. Eg. 3-7 m/min where as the
control instrument is different. Need system correction and shall be
7 compliance with work instruction
240 A
work rest blade thickness 1-3 - how it is selected The procedure to be addressed in the work
8 instruction

Feed rate shown in control instrument is 45 sec where as in Need system correction and shall be
9 control plan/sop specifies met/min. compliance with work instruction

Need system correction

10 SOP 02 does not address the recording details .

work instruction will be modified to address

specified only the limited parameters . Where as all the modified all the DOE approved parameters with details.
11 parameters through DOE including maintanence parameters are Work instruction to be corrected.
not addressed in the SOP.

Rough Grinding
 Rough Grinding sop does not address the work rest plate height as per control Work instruction to be modified to address
plan. the work rest plate details. Measuring gauge
will be introduced
12 Work rest blade height is not measured and no gauge available.

Calibration not evidenced for refractrometer. Refractrometer to be calibrated either by

manufacturer.
SWIL will introduce a internal calibration
13 procedure.

Daily verification of concentration of coolant is not evidenced. concentration verification shall be introduced
as a part of first off inspection and recorded.
Control plan and work instruction will address
14 the same .

RI beginning of the shift 5 times to be recorded , where as it Need to conformance.

15 marked with one reading.
Rest plate thickness - how it will be selected for thickness which
is not addressed in WI Verification method to be addressed in the
16 SOP.
specified only the limited parameters . Where as all the modified
parameters through DOE including maintanence parameters are
220 D Two roller straightening not addressed in the SOP.
since angle setting parameters is critical the
17 angle plate to be corrected with clear
readability and calibration by internal.

Feed rate different scale followed. Eg. 3-7 m/min where as the Need system correction and shall be
18 control instrument is different.
compliance with work instruction
work rest blade thickness 1-3 - how it is selected how. The procedure to be addressed in the work
19 instruction

Feed rate shown in control instrument is 45 sec where as in Need system correction and shall be
20
control plan/sop specifies met/min. compliance with work instruction
Need system correction
21 SOP 02 does not address the recording details .
work instruction will be modified to address
all the DOE approved parameters with details.
specified only the limited parameters . Where as all the modified Work instruction to be corrected.
22 parameters through DOE including maintanence parameters are
not addressed in the SOP.

sop does not address the work rest plate height as per control Work instruction to be modified to address
240 B Pre final grinding plan. the work rest plate details. Measuring gauge
Work rest blade height is not measured and no gauge available. will be introduced
23
 240 B Pre final grinding

Calibration not evidenced for refractrometer. Refractrometer to be calibrated either by

manufacturer.
SWIL will introduce a internal calibration
24 procedure.

Daily verification of concentration of coolant is not evidenced. concentration verification shall be introduced
as a part of first off inspection and recorded.
Control plan and work instruction will address
25 the same .

RI beginning of the shift 5 times to be recorded , where as it

26 marked with one reading. Need clarification and compliance.

Rest plate thickness - how it will be selected for thickness which

is not addressed in WI Verification method to be addressed in the
27 SOP.

specified only the limited parameters . Where as all the modified

220E Two roller straightening parameters through DOE including maintanence parameters are
not addressed in the SOP. since angle setting parameters is critical the
28 angle plate to be corrected with clear
readability and calibration by internal.

Feed rate different scale followed. Eg. 3-7 m/min where as the
control instrument is different. Need system correction and shall be
29
compliance with work instruction

work rest blade thickness 1-3 - how it is selected how. The procedure to be addressed in the work
30 instruction

Feed rate shown in control instrument is 45 sec where as in Need system correction and shall be
31 control plan/sop specifies met/min. compliance with work instruction

Need system correction

32 SOP 02 does not address the recording details .
work instruction will be modified to address
all the DOE approved parameters with details.
specified only the limited parameters . Where as all the modified Work instruction to be corrected.
33 parameters through DOE including maintanence parameters are
not addressed in the SOP.
240C Final Grinding

sop does not address the work rest plate height as per control Work instruction to be modified to address
plan. the work rest plate details. Measuring gauge
34 Work rest blade height is not measured and no gauge available. will be introduced

Calibration not evidenced for refractrometer. Refractrometer to be calibrated either by

manufacturer.
SWIL will introduce a internal calibration
35 procedure.
 Daily verification of concentration of coolant is not evidenced. concentration verification shall be introduced
as a part of first off inspection and recorded.
36 Control plan and work instruction will address
the same .
Rest blade height specification not addressed in WI.
37 Need clarification and compliance.

SOP 02 does not address the recording details .

38 To be addressed in the system.
Operator qualified as Level I , where in for certification or
authorization level II is required. This is to be complied as per ASM or DIN
39 requirement.
Operator qualification requirement is not referred in Work
instruction.
Operator qualification / requirement as per
40 ASM to be addressed in the work instruction.
Crack detection - Eddy
current.
Master verification is recorded but the same is not addressed in
the system (WI/control plan) work instruction will address the recording of
41 daily master verification /shift wise.
Out of 136 bars 5 bars are rejected . There is no evidence of
root cause analysis and corrective action. Daily analysis will be carried out and recorded
42 250
for any rejection above the target/ high cost .

In LPI - Automatic inspection through soft ware - wrongly

43 mentioned. control plan will be corrected .

corrective action . (Route card verification will

44 Nirova material ZYGLO is not carried out as per control plan be addressed for each batch )
Work instruction will be addressed in the
45 WI not referred in control plan
LPI control plan.

Rejection material storage is next not accepted material in ZYGLO Rejection /Rework storage area will be re
46
. NEED immediate locate change for further mix up. located with control .

Work instruction will be made available at

47 Work instruction not available at the work station. the work station.
CSR will be prepared as per the APQP
48 There is no CSR for dimension for Nirova material
requirement.
For roundness - marked as critical characteristics and checked
49 Roundsss results will be recorded .
100% but not recorded.

Regarding Length of bar verified 100% - Measurement system is

Length measurement will be marked with
50 attribute data and need defined instrument or mark for different reading for each meter and final with CM.
length.
260 Dimensional inspection
Rejected material stored separately with yellow paint . Colour
code is wrong. Colour code will be listed at the work station
for rejection, rework and acceptance
51
according and the same will be addressed in
the work instruction.

Length inspection . NO tolerance is specified.

Length requirement , tolerance will be
52 addressed in the WI and control plan.

Skill matrix will be displayed in the respective

station with operators details and required
Operator qualification and skill report report and actual not
53 skill with actual skill 29.02.2020 Manwesh
evidenced at the work station.

270 Mix-up Test

 270 Mix-up Test
Chemical composition chart is not evidenced at the work station Chemical composition grade with material
54 details and the identification elements will be Rajneesh/Tiw
as per work instruction WI/VS/QA/11 displayed at the Mix up test work station. ari

Visual Aid of Mix up test by X Mat SWIL/VA/VS/INS/07/02 is not Visual Aid chart will be displayed at the work Rajneesh/
55 provided at the work station. station Tiwari

Length requirement as 3900 - 4000 mm with min and max .

There is no defined gauge addressed to control within the Length measurement will be marked with
56 reading for each meter and final with CM.
tolerance
End cutting and length
280 cutting.
End squareness measurement marked as visual where as the
Need discussion since end squareness is
57 requirement is given as 0.50 mm max. Wrongly addressed in critical. This can lead
control plan

R.P. Application & Reference std given as ASTM 388 . SOP to address the master Verification of master sample in UT will be
58 Ultrasonic Testing. sample details with setting parameters. addressed in the SOP and shall be recorded.

Quarantine area and identification and tracebility is not Quarantine area will be identified and the
59 290 respective material will be marked for
evidenced. identification and traceability.

SOP to address all the initial setting parameters with material SOP will address all the setting parameters in
60 grade . the UT machine
Rajneesh/
No check list available as per work instruction WI/VS/QA/13, Colour code check list as per the work Tiwari
61 instruction will be provided at the work
Bundling and packing. station and shall be verified

Approval and verification will be carried out Rajneesh/

300 Colour coding with sign off and authorization report as per Tiwari
No sign off and authorization evidenced as per work instruction work instruction
62 WI/VS/QA/13 29.02.2020

Material found non conformances are stored in a Rework area Identification and verification check list will be Rajneesh/
63 29.02.2020 Tiwari
and material kept without identification. introduced.
Rajneesh/
Verification of identification and tracebility Tiwari
some bundles are found with identification and tracebility
64 material 21-4N will be included as the part of bundling and 29.02.2020
packing list

Verification of no of straps will be addressed Rajneesh/

in the bundling and packing list. Tiwari
65 310 Bundling and packing As per work instruction the bundle will be strapped 6 places 29.02.2020
where as it is strapped more than 8 places.

Verification of no of straps will be addressed Rajneesh/

Heat number is not evidenced on the bundle . Identified with in the bundling and packing list. Tiwari
66 dia, material, but stored along with other bundles. 29.02.2020

Rajneesh/
Tiwari
Work instruction will be provided at the
Transfer to finish good For operation 310 i.e. Transfer to finish good area and dispatch , respective work stations.
67 100 E area and dispatch for which no work instruction is available at the work station. The same will be verified as the part of Daily 29.02.2020
Routine Management during the approval.
 Process Audit observation for Processes Mix up test, Colour coding. SWIL Plant 2 - 07.02.2020

No. Process Process Not conformances. Corrective action Target date Resp.
number
Skill matrix will be displayed in the respective
station with operators details and required
1 280 Mix-up Test Operator qualification and skill report report and actual not skill with actual skill 29.02.2020 Manwesh
evidenced at the work station.

Chemical composition grade with material

Chemical composition chart is not evidenced at the work station
2 details and the identification elements will be Rajneesh/Tiwari
as per work instruction WI/VS/QA/11
displayed at the Mix up test work station.

Visual Aid of Mix up test by X Mat SWIL/VA/VS/INS/07/02 is not Visual Aid chart will be displayed at the work Rajneesh/ Tiwari
3
provided at the work station. station
Rajneesh/ Tiwari
Colour code check list as per the work
4 290 Colour coding No check list available as per work instruction WI/VS/QA/13, instruction will be provided at the work
Bundling and packing.
station and shall be verified

Approval and verification will be carried out Rajneesh/ Tiwari

with sign off and authorization report as per
No sign off and authorization evidenced as per work instruction work instruction
5 29.02.2020
WI/VS/QA/13

Material found non conformances are stored in a Rework area Identification and verification check list will be Rajneesh/ Tiwari
6 29.02.2020
and material kept without identification. introduced.
Rajneesh/ Tiwari
Verification of identification and tracebility
Bundling and some bundles are found with identification and tracebility
7 300 will be included as the part of bundling and 29.02.2020
packing material 21-4N
packing list

Verification of no of straps will be addressed Rajneesh/ Tiwari

As per work instruction the bundle will be strapped 6 places in the bundling and packing list.
8 29.02.2020
where as it is strapped more than 8 places.

Verification of no of straps will be addressed Rajneesh/ Tiwari

Heat number is not evidenced on the bundle . Identified with in the bundling and packing list.
9 29.02.2020
dia, material, but stored along with other bundles.

Rajneesh/ Tiwari
Transfer to Work instruction will be provided at the
finish good For operation 310 i.e. Transfer to finish good area and dispatch , respective work stations.
10 310 29.02.2020
area and for which no work instruction is available at the work station. The same will be verified as the part of Daily
dispatch Routine Management during the approval.