Project-4- Receipt & Process Quality Improvement.

Project Owner:- Navneet Kumar

Project Expected Budget Team

Sr. Title Problem Statement/Purpose Impact Measurable Result Major actions involved Remarks Involved Dept Leader Priority Start Date

→ Improve product quality → Management approval

4& Validation of In house testing method and testing → Reduce customer complaints and in-house issues >90% achievement of Plan →Define Responsibilities in team Yes QA Navneet High 01.02.2020
58 infrastructure in line with field requirement
→ Improve process quality

Closer of Customer Complaints

→ Improve product quality >80% Closer of Customer
10 APLV Diaphragm rubber quality poor; Need to Complaints within time Weekly review of SQPR by CFT team …….. QA Navneet High 01.02.2020
improve the quality of Diaphragm to stop the failure. → Reduce customer complaints and in-house issues frame

Closer of Customer Complaints

G-21 MAGNET VALVE:- Armature rubbing from inside
and Sticky operation, need to change the armature → Improve product quality
material or to replace it with the material whose → Reduce customer complaints and in-house issues >80% Closer of Customer
11 wear and tear should be less and act it G21 Magnet → Reduce in process rejection Complaints within time Weekly review of SQPR by CFT team …….. QA Navneet High 01.02.2020
Coil smoothly for sliding operation. (Stickiness was frame
the major issue just because of the rubbing of
armature with the Cartridge).

Closer of Customer Complaints

LHB Secondary Lateral Damper due to Silent block → Improve product quality
bushes worn out, Need to increase the Outer Dia. Of → Reduce customer complaints and in-house issues >80% Closer of Customer
12 silent block rubber bush and decrease the Inner Dia. → Improve process quality Complaints within time Weekly review of SQPR by CFT team Closed …….. QA Navneet High 01.02.2020
Of Holding Position of Silent Block .(For less wear and → Improve Product Reliability frame
tear need to improve the quality of Silent block.) → Reduce in process rejection

Closer of Customer Complaints

LHB Secondary Vertical Damper due to Silent block → Improve product quality
bushes worn out, Need to increase the Outer Dia. Of → Reduce customer complaints and in-house issues >80% Closer of Customer
13 silent block rubber bush and decrease the Inner Dia. → Improve process quality Complaints within time Weekly review of SQPR by CFT team Closed …….. QA Navneet High 01.02.2020
Of Holding Position of Silent Block .(For less wear and → Improve Product Reliability frame
tear need to improve the quality of Silent block.) → Reduce in process rejection

Closer of Customer Complaints

Safety valve failure (Old Design):- Safety valve spring
broken, Due to heavy tension on spring of Safety → Improve product quality
Valve it brakes into 2 Pieces. Need to change in the → Reduce customer complaints and in-house issues >80% Closer of Customer
14 designing point of view, as we are using the spring in Complaints within time Weekly review of SQPR by CFT team …….. QA Navneet High 01.02.2020
the tension format, requirement of Compression frame
spring in the Safety valves solves the issue of Spring
failure.

Closer of Customer Complaints

Safety valve failure (Modified New Design):- Safety → Improve product quality
valve spring broken, As its strength is too low to → Reduce customer complaints and in-house issues
handle the Air pressure, Due to heavy tension on
spring of Safety Valve it brakes into 2 Pieces. Need to >80% Closer of Customer
15 change in the designing point of view, as we are Complaints within time Weekly review of SQPR by CFT team …….. QA Navneet High 01.02.2020
frame
using the spring in the tension format, requirement
of Compression spring in the Safety valves solves the
issue of Spring failure.

Closer of Customer Complaints

Triple Valve K ring parts no-N894/14.8 found with → Improve product quality
uneven finishing/scratch mark. It is suspected that → Reduce customer complaints and in-house issues
the above defects of material in K Ring causes
leakage from EP Unit. Hardness of rubber >80% Closer of Customer
16 component (K-Ring) is more; need to replace it with Complaints within time Weekly review of SQPR by CFT team …….. QA Navneet High 01.02.2020
less hardness of rubber component to arrest the frame
issue of leakage (As the K-Ring was not properly
expands into located area to stop the air pressure
therefore leakage takes place).
Project -
Customer
Complaint &
Testing
Validation

008000 Classification | ESCORTS-INTERNAL

Sr. Project Problem Statement/Purpose Impact Expected Major actions involved Remarks Budget Dept Team Priority Start Date
Title Measurable Result Involved Leader
Project -
Customer Closer of Customer Complaints
Complaint &
Testing Distributors Valves Brake cylinder pressure rise up → Improve product quality
Validation suddenly B.C Pressure of D.V. found 3.5 kg/cm2. As → Reduce customer complaints and in-house issues
the failure occurs due to spring tension/compression >80% Closer of Customer
17 Complaints within time Weekly review of SQPR by CFT team …….. QA Navneet High 01.02.2020
vary, therefore use HDBT in the Distributor valve to frame
arrest the issue or design the perfect spring as its not
vary the Brake Cylinder pressure.

Closer of Customer Complaints

WAG -9 LOCO Axle Damper :- Piston rod welding → Improve product quality
crack resulting into piston dangling. As the piston → Reduce customer complaints and in-house issues >80% Closer of Customer
18 should be properly weld onto it's core as it will not Complaints within time Weekly review of SQPR by CFT team Closed …….. QA Navneet High 01.02.2020
fail into the service and piston dangling issue will get frame
arrest.

Closer of Customer Complaints

WAG -9 LOCO Vertical Damper :- Damper Uncouple → Improve product quality >80% Closer of Customer
19 from top bracket. Top bracket should be properly → Reduce customer complaints and in-house issues Complaints within time Weekly review of SQPR by CFT team Closed …….. QA Navneet High 01.02.2020
weld onto it's core. frame

Closer of Customer Complaints

WAG -9 LOCO YAW DAMPER:- Damper failure → Improve product quality >80% Closer of Customer
20 observed OIL LEAKAGE issue. Need to improve → Reduce customer complaints and in-house issues Complaints within time Weekly review of SQPR by CFT team Closed …….. QA Navneet High 01.02.2020
quality of OIL seal. frame

Closer of Customer Complaints

ADMBS Roller Lever Valve:- Roller Lever Valve found → Improve product quality
leak in Power Car 181152, The valve was leak → Reduce customer complaints and in-house issues
continuously in Brake application and release
condition. After overhauling observed that K-Ring of >80% Closer of Customer
21 valve are damage due to rubbing action. Due to Complaints within time Weekly review of SQPR by CFT team …….. QA Navneet High 01.02.2020
damage of K-ring roller Lever valve leak continuously. frame
As the K-Ring Hardness is less and internal bush
having wholes, it's sharpness was more due to that
K-Ring damages and leakage takes place.

ADMBS/Dump Valve:- Strainer (Filter) need to be Closer of Customer Complaints

fitted into the incoming and outgoing port of Dump >80% Closer of Customer
22 Valve as its avoid to entre the dust particle into the → Improve product quality Complaints within time Weekly review of SQPR by CFT team …….. QA Navneet High 01.02.2020
→ Reduce customer complaints and in-house issues
Dump Valve for ignore the continuous leakage from frame
the Dump Valve.
Closer of Customer Complaints
Air Suspension Hose Pipe/Levelling Valve (Make :
Gates):- Air Suspension Hose Pipe used in the → Improve product quality >80% Closer of Customer
23 Levelling Valve not having crimping properly, Advise → Reduce customer complaints and in-house issues Complaints within time Weekly review of SQPR by CFT team …….. QA Navneet High 01.02.2020
to properly crimp the hose pipe as it's not came out frame
easily from the attachment of Levelling valve.

Closer of Customer Complaints

ADMBS/ CALIPER BOLT:-Calliper bolt of Brake >80% Closer of Customer
Cylinder was missing as it's not providing the locking → Improve product quality
24 washer into it. Missing bolts of calliper unit issue was → Reduce customer complaints and in-house issues Complaints within time Weekly review of SQPR by CFT team …….. QA Navneet High 01.02.2020
major one and happened frequently. frame

ADMBS/Passenger Emergency Valve:-Passenger Closer of Customer Complaints

emergency valve having Choke inside it, due to heavy >80% Closer of Customer
25 dust cover the choke port leakage takes place. → Improve product quality Complaints within time Weekly review of SQPR by CFT team …….. QA Navneet High 01.02.2020
Strainer (Filter) need to be fitted into the incoming → Reduce customer complaints and in-house issues frame
line of Valve to avoid such issue.
Closer of Customer Complaints
EPC/PRESSURE LIMITING VALVE:- The PLV pre-B.C.
pressure not maintained which is 3.6 kg/cm2 and → Improve product quality >80% Closer of Customer
26 goes beyond 3.9 kg/cm2. Spring inside of PLV need → Reduce customer complaints and in-house issues Complaints within time Weekly review of SQPR by CFT team …….. QA Navneet High 01.02.2020
to be improve to set the B.C. Pressure within frame
permissible limit (3.6 ± 0.1 kg/cm2).

→ Management approval
→ Reduce manual error during inspection and reduction → List out required gauges
2 Establishmen Introduction of gauges to reduce inspection time. in inspection time . >90% achievement of Plan → Drawing preparation from PE and Yes QA Navneet High 01.02.2020
t of →Reduction in Rejection. Manufacturing of Gauges
measuremen → Procurement of gauges
t / testing
facility 008000 Classification | ESCORTS-INTERNAL
 Project
Sr. Establishmen Problem Statement/Purpose Impact Expected Major actions involved Remarks Budget Dept Team Priority Start Date
t of Title Measurable Result Involved Leader
measuremen
t / testing
facility → Improve product quality 100% completion of
Full arrangement of testing facilities including all → Reduce customer complaints
48 required test benches for all products Planned activities within List out activities Yes QA Navneet High 01.02.2020
time frame
Authorization to QA to shift suspected material in →Reduction in customer complaints 100% completion within →Request generation to IT and follow till
5 Oracle from current location to different location to → Reduction in warranty failure time frame action completion …….. QA Navneet High 01.02.2020
avoid issuance / usage

→ Improve product quality

6& Initiate detailed Process Audit in line with Control → Reduce customer complaints and in-house issues →Preparation of process audit plan and
→ Improve process quality 100% achievement of Plan …….. QA Navneet High 01.02.2020
32 Plan / QAP / Drawing → Improve Product Reliability adherence of planned audit schedule
→ Reduce in process rejection

→ Improve product quality

Closure of → Reduce customer complaints and in-house issues
9 >80% Closer of SQPR within Weekly review of SQPR by CFT team
SQPR, In SQPR closure to be reviewed by CFT → Improve process quality
time frame
…….. QA Navneet High 01.02.2020
House CAPA → Improve Product Reliability
& Audit NC → Reduce in process rejection

27 Start thing:- If any quality issue occur during >90% Closer ( Containment Inline activity can be done by process
& assembly then segregation start from assembly line Quick containment Vs line quality issue action ) of line issue within Weekly review of Line issue quality with support from Receipt …….. QA Navneet High 01.02.2020
28 to store location time frame Inspection & SQA.
At Stores to be done by SQA.

→ Improve product quality

30 Start thing:- CAPA should be adhere and close with in → Reduce customer complaints and in-house issues >80% Closer of In house
& time frame → Improve process quality CAPA within time frame Weekly review of CAPA by CFT team …….. QA Navneet High 01.02.2020
51 → Improve Product Reliability
→ Reduce in process rejection

→Reduction in Rejection.
3 Product FAI with all supporting documents for Final → Enhance product reliability by validation of Mfg. 100% achievement of Plan → List out product for FAI …….. QA Navneet High 01.02.2020
product →Define Responsibilities in team
process & product before release to production
→ Improve product quality 100% completion of
Stop Things- Unchecked (individually) CPBs should → Reduce customer complaints
34 not be coupled with DV and despatched. Planned activities within List out activities Yes QA Navneet High 01.02.2020
→ Reduce in process rejection time frame
→ Improve product quality
→ Reduce customer complaints and in-house issues >80% Closer of Rubber
35 Start Things-Quality of Rubber should be improved → Improve Product Reliability quality issue within time List out of rubber quality issue . …….. QA Navneet High 01.02.2020
immdly. Seal for CPB (Pt-196) & Seal (Pt no-77) → Reduce in process rejection frame

→ Improve product quality

39 Start Things- Wire Rope for Hand Brakes- Length of → Reduce customer complaints 100% completion of
& Wire Rope should be increased by 100 mm immdly → Reduce in process rejection Planned activities within List out activities Yes QA Navneet High 01.02.2020
40 to ensure easy fitment of Hand Brake Cables & time frame
current Length should not be sent in the Sets

→ Improve product quality

Start Things- Overall Quality of Dampers- Quality of → Reduce customer complaints
41 Welding is to be improved. Regular checks at → Reduce in process rejection >90% achievement of Plan Preparation of audit check sheet …….. QA Navneet High 01.02.2020
Vendors end must be ensured.

→ Improve product quality

→ Reduce customer complaints 100% completion of
45 100 % inspection of each item from supplier → Reduce in process rejection Planned activities within List out activities Yes QA Navneet Medium
→ Improve product reliability time frame

46 → Improve product quality 100% completion of

→ Reduce customer complaints Gaps to be Identified & closure of activity in
& Zero deviation in respect to drawing. Planned activities within List out activities 15 dayds after opening. ---- QA Navneet High 01.02.2020
49 → Reduce in process rejection time frame
100% completion of
47 Aesthetic look of products should be improved to Improve performance & aesthetic look of product Planned activities within List out activities Yes QA Navneet Medium
Process compete with international quality standard.
time frame
Improvemen
t (FAI / First → Improve product quality
Pc. → Reduce customer complaints
50 Approval / Start Things-Gauge R&R as system → Reduce in process rejection >90% achievement of Plan Preparation of Plan for implementation ---- QA Navneet Low
Visual
Inspection /
Aesthetic
Look / Gauge
R&R / RI
Activity)
008000 Classification | ESCORTS-INTERNAL
 Process
Improvemen
t (FAI / First
Pc.
Sr. Project/
Approval
Problem Statement/Purpose Impact Expected Major actions involved Remarks Budget Dept Team Priority Start Date
Visual
Title /
Inspection Measurable Result Involved Leader
Aesthetic
Look / Gauge → Improve product quality
R&R / RI Proper coordination between RI & Process QA, What → Reduce line complaints
52 Activity) ever material which is cleared from RQI should not → Reduce in process rejection 100% completion of
& have any quality issues . Rotation / inter change of Planned activities within List out activities ---- QA Navneet High 01.02.2020
55 line quality team with RQI to improve / better time frame
exchange of info to control defects

→ Improve product quality

Expectation :- Rubber items shelf life to be checked by QA → Reduce customer complaints 100% completion of
56 while time of receipt and same quarter material is → Reduce in process rejection Planned activities within List out activities ---- QA Navneet High 01.02.2020
expected in same month . Month and year of supply details
to be available on all rubber material on the packing . time frame

CTQ ( Control to Quality) dimensions/parameters to → Improve product quality 100% completion of

57 be identified and incorporated in check sheets → Reduce customer complaints Planned activities within List out activities Yes QA Navneet High 01.02.2020
involve CFT team → Reduce in process rejection time frame
→ Improve product quality
To have expertise team in Quality group to check → Reduce customer complaints 100% completion of
59 Electronics parts → Reduce in process rejection Planned activities within List out activities Yes QA Navneet Medium
→ Improve product reliability time frame

→ Improve product quality

Drawing deviations to be highlighted and discussed → Reduce customer complaints 100% completion of
60 for manufacturing feasibility → Reduce in process rejection Planned activities within List out activities ---- QA Navneet Medium
→ Improve product reliability time frame

→ Improve product quality

In-process Quality Improvement: → Reduce customer complaints 100% completion of
61 Patrol inspection to be executed to monitor the → Reduce in process rejection Planned activities within List out activities ---- QA Navneet High 01.02.2020
quality of product (at sub-assembly / assembly level). time frame

→ Improve product quality Special process First piece approval will

→ Reduce customer complaints 100% completion of
62 In-process Quality Improvement: First piece Planned activities within List out activities generate lot of scrap as in our case it is Yes QA Navneet High 01.02.2020
approval for special process to be established → Reduce in process rejection destructive testing for welding .
→ Improve product reliability time frame Decision need to be taken

008000 Classification | ESCORTS-INTERNAL

 ocess Quality Improvement.
er:- Navneet Kumar

Completion Status as on
Date 25.01

30.05.2020

30.07.2020

30.07.2020

30.07.2020

30.07.2020

31.07.2020

30.07.2020

30.07.2020

008000 Classification | ESCORTS-INTERNAL

 Completion Status as on
Date 25.01

31.07.2020

30.07.2020

30.07.2020

31.07.2020

30.07.2020

30.07.2020

30.07.2020

31.07.2020

30.07.2020

30.07.2020

30.07.2020

008000 Classification | ESCORTS-INTERNAL

 Completion Status as on
Date 25.01

30.12.2020

30.04.2020

30.07.2020

30.04.2020

31.03.2020

30.05.2020

30.07.2020

30.03.2020

30.04.2020

30.03.2020

30.05.2020

30.03.2020

008000 Classification | ESCORTS-INTERNAL

 Completion Status as on
Date 25.01

30.07.2020

30.03.2020

30.07.2020

30.04.2020

30.06.2020

008000 Classification | ESCORTS-INTERNAL

 Remarks
Suggestions from : Quality
Responsible Category (Expection / Start H/M
Sl No. Item A/I/P JDI
Person things / Stop things) /L
Oracle system Production entry & Quality clearance at Production /
1 P H JDI
different Gate as per Job Order QA
2 ORC system should be in Oracle PPC P M

3 Initiate Operator Self visual inspection during production Production A H

Testing ownership by operator to avoid repetition of

4 Production A H JDI
testing
Qualified operators identification on critical assembly
5 Production A H
stations.
Availability of latest drawings on server with read only
6 TBC P M
access (no copy, no print option)
Kitting system to be introduced so that no missing parts
7 PPC / Store P M
are missing in final assembly.
8 Introduction of gauges to reduce inspection time. QA P
Preparation of SOP / WI for different testing processes
9 like painting, pull test, welding test, leakage test etc. PE / QA
which are man dependent.
Acceptance criteria required for visual welding,
10 aesthetics, paint finish etc. PE / QA

Actual detailed PFMEA and Control plan with critical

11 parameters identified. PE

12 APQP to be started NPD / SQA

Exploded view of each assemblies to check orientation
13 Production
and any part missing.
PE /
14 Implementation of Pictorial work instruction of assembly
Production
Product FAI with all supporting documents for Final QA /
15
product Production

Work order (SOS+Customer approved Drawing) to be

moved along with the component to avoid wrong Marketing +
16
assembly of parts (example- wrong handle assembled in PPC
export DV)

Feasibility to be explored foer pick sencor system at PE /

17 asssembly area Production
18 Introduce child part traceability SQA / Store
Hologram pasting activity should not be with QA to
19 avoid unnecessary engagement of QA inspector instead TBC
of In Process inspection
Implementation of Product History card with child part
20 Production
treaceability
5S of shops & Store to be improved to overcome Production /
21
material mix and part to part handling damage. Store
Validation of In house testing method and testing Service /
22
infrastructure in line with field requirement R&D
Authorization to QA to shift suspected material in Oracle
23 from current location to different location to avoid TBC
issuance / usage
Implementation of FIFO in metal parts to avoid rust
24 formation Store

All rubber parts should be stored in Dark room (Hose,

25 Store
Seal, Gasket etc.)
Initiate detailed Process Audit in line with Control Plan /
26 QA
QAP / Drawing
27 Explore internal NCR/SQPR/CRS in Oracle / Portal IT
Assembly test bench digitalization to overcome the man Production /
28
dependancy PE

008000 Classification | ESCORTS-INTERNAL

 Water Jet cleaning of critical parts (castings, manifolds Production /
29
etc.) SQA
30 Finish goods area should be separate. Production
Pokayoke at pressing stages to ensure proper
31 interference condition PE

Packing standard to be reviewed at child & finish level

32 Store / SQA
product
33 Audit of rubber room for shelf life monitoring Store
Automail should go to supplier through Oracle in case of
34 IT / QA
rejection booking
35 Reconsilation of OSP rejection on monthly basis Materials
36 Conversion of OSP items to BOP Materials
Special processes to be done at Escorts approved Materials /
37 suppliers SQA
Review of supplier processes w.r.t. FAI documents at
38 supplier site including SIA preparation NPD / SQA

Top
Explore the possibility to hire commodity experts
39 Managemen
(Metallurgy, Welding, Painting, Rubber, Electronics etc.)
t

Product training to be provided to respective people by Service /

40 covering working principle of product and its child parts R&D

Regular training to be provided to shop floor employees QA /

41
to generate Quality culture Production
Require dedicated person for timely entry & monitoring
42 Service
of customer complaint
43 SQPR closure to be reviewed by CFT CFT
44 Meet/ Exceed Customer requirement Expectation I
Review progress or Closure of last meeting identfied
45 Start Things I
gaps with Set frequency.
Start GEMBA & Quality Circle-- Team Members should
46 be part of CFT in Problem Solving. Start Things I
"Quality is responsibility of all"

Review Suppliers Performance and take action on

47 - SOB Start Things
- Consolidation
48 Awarding Business to Problomatic suppliers. Stop Things
In house Process with inadequate
49 Stop Things
tools/Instruments/Gauges/ Handling/Skill etc.

APLV Diaphragm rubber qulity

50 APLV poor; Need to improve the quality
of Diaphragm to stop the failure.

Armature rubbing from inside and

Sticky operation, need to change
the armature material or to
replace it with the material whose
wear and tear should be less and
51 G-21 MAGNET VALVE act it G21 Magnet Coil smoothly
for sliding operation. (Stickyness
was the major issue just because
of the rubbing of armature with
the Cartridge).

008000 Classification | ESCORTS-INTERNAL

 LHB Secondary Lateral Damper
due to Silent block bushes worn
out, Need to increase the Outer
Dia. Of slient block rubber bush
52 LHB Secondary Lateral Damper and decrease the Inner Dia. Of
Holding Position of Silent Block .
(For less wear and tear need to
improve the quality of Silent
block.)

LHB Secondary Vertical Damper

due to Silent block bushes worn
out, Need to increase the Outer
Dia. Of slient block rubber bush
53 LHB Secondary Vertical Damper and decrease the Inner Dia. Of
Holding Position of Silent Block .
(For less wear and tear need to
improve the quality of Silent
block.)

Safety valve spring broken, Due to

heavy tension on spring of Safety
Valve it brakes into 2 Pieces. Need
to change in the desiging point of
54 Safety valve failure (Old Design) view, as we are using the spring in
the tesion format, requirement of
Compression spring in the Safety
valves solves the issue of Spring
failure.

Safety valve spring broken, As its

strength is too low to handle the
Air pressure, Due to heavy tension
on spring of Safety Valve it brakes
into 2 Pieces. Need to change in
55 Safety valve failure (Modified New Design) the desiging point of view, as we
are using the spring in the tesion
format, requirement of
Compression spring in the Safety
valves solves the issue of Spring
failure.

Triple Valve K ring parts no-

N894/14.8 found with uneven
finishing/scratch mark.It is
suspected that the above defects
of material in K Ring causes
leakage from EP Unit. Hardness of
rubber component (K-Ring) is
56 Triple Valve
more; need to replace it with less
hardness of rubber component to
arrest the issue of leakage (As the
K-Ring was not properly expands
into located area to stop the air
pressure therefore leakage takes
place).

008000 Classification | ESCORTS-INTERNAL

 Distributors Valves Brake cylinder
pressure rise up suddenly B.C
Pressure of D.V. found 3.5
kg/cm2. As the failure occurs due
to spring tension/compression
57 Distributors Valves
vary, therefore use HDBT in the
Distributor valve to arrest the
issue or design the perfect spring
as its not vary the Brake Cylinder
pressure.

Piston rod welding crack resulting

into piston dangling. As the piston
should be properly weld onto it's
58 WAG -9 LOCO Axle Damper
core as it will not fail into the
service and piston dangling issue
will get arrest.

Damper Uncouple from top

59 WAG -9 LOCO Vertical Damper bracket. Top bracket should be
properly weld onto it's core.

Damper failure observed OIL

60 WAG -9 LOCO YAW DAMPER LEAKAGE issue. Need to improve
quality of OIL seal.

Roller Lever Valve found leak in

Power Car 181152, The valve was
leak continuously in Brake
application and release condition.
After overhauling observed that K-
Ring of valve are damage due to
61 ADMBS Roller Lever Valve rubbing action. Due to damage of
K-ring roller Lever valve leak
continuously. As the K-Ring
Hardness is less and internal bush
having wholes, it's sharpness was
more due to that K-Ring damages
and leakage takes place.

Strainer (Filter) need to be fitted

into the incoming and outgoing
port of Dump Valve as its avoid to
62 ADMBS/Dump Valve entre the dust particle into the
Dump Valve for ignore the
continuous leakage from the
Dump Valve.

Air Suspension Hose Pipe used in

the Levelling Valve not having
Air Suspension Hose Pipe/Levelling Valve (Make : crimping properly, Advise to
63
Gates) properly crimp the hose pipe as
it's not came out easily from the
attachment of Levelling valve.

Caliper bolt of Brake Cylinder was

missing as it's not providing the
locking washer into it. Missing
64 ADMBS/ CALIPER BOLT
bolts of caliper unit issue was
major one and happened
frequently.

008000 Classification | ESCORTS-INTERNAL

 Passenger emergency valve
having Choke inside it, due to
heavy dust cover the choke port
65 ADMBS/Passenger Emergency Valve leakage takes place. Strainer
(Filter) need to be fitted into the
incoming line of Valve to avoid
such issue.
The PLV pre-B.C. pressure not
maintained which is 3.6 kg/cm2
and goes beyond 3.9 kg/cm2.
Spring inside of PLV need to be
66 EPC/PRESSURE LIMITING VALVE
improve to set the B.C. Pressure
within permissible limit (3.6 ± 0.1
kg/cm2).

All materail should be come assembly lines after 100%

67 Expection I
inspection from back end
All Child component packing should be removed just
68 before assembly (Net packing preferred) Expection A

69 Process setup should be freezed for each component Expection A

All movement trollies should be non metal to metal

70 concept basis Expection

New manpower product training should be given before

71 Expection
deput to shop
Proper storage area for final component storage(Fiba &
72 Expection
Amdbs)
73 Preventive maintenance of machine adhere timely Expection
74 Customer complaint ledger to be maintain Expection

If any quality issue occur during assembly then

75 Start thing
segrigation start from assembly line to store location

Immidiate action should be taken if any quality issue

77 raise during assembly Start thing

78 Rejection disposal practice should start on daily basis Start thing

Skill manpower deputation required for critical and

79 Start thing
normal operation
Materail supply from store to assembly line should be in
80 Start thing
bins instead of trollies

81 CAPA should be adhere and close with in time frame Start thing

82 5S improve Start thing

83 Tool & fixture inspection sholud be start before installing Start thing

84 First piece approval should be start for each component Start thing

85 Process control audit component wise should be start Start thing

86 Supplier reworking at escorts premises Stop thing

Final assy reworking area should be separate from
87 Stop thing
assembly lines
Poor handling of materail in shop floor (over-lapping,
88 Stop thing
materail on floor)
89 Common Pipe Bracket Air Brakes

Start Things- Receipt Inspection of

CPB Casting needs to be
90
tightened. 100 % CPB must be
checked individually.

008000 Classification | ESCORTS-INTERNAL

 Stop Things- Unchecked
91 (individually) CPBs should not be
coupled with DV and despatched.

Start Things-Quality of Rubber

92 Seal for CPB (Pt-196) & Seal (Pt no-77)
should be improved immdly.

Stop Things- Existing Seals should

93 not be used in New DVs.
Start Things- Month & Year of Mfg
for all incoming Hose Couplings
94 Hose Couplings BP & FP Must be checked , which should
be of current lots.
Stop Things- Hose Couplings
should not be sent with Air Brake
95
sets without checking the Month
& Year of Mfg.

Start Things- Length of Wire Rope

should be increased by 100 mm
96 Wire Rope for Hand Brakes
immdly to ensure easy fitment of
Hand Brake Cables.

Stop Things- Wire Rope of current

97 Length should not be sent in the
Sets

Start Things- Must introduce

98 Unified Design of BMBS Brak Cylinder
unified design of BMBS Cylinders.

Stop Things- We should not have

different type of Brake Cylinders
for different type of Wagons. This
99 is creating tremendous amount
confusion both at our end as well
as customer end. This should not
continue.

Start Things- Quality of Welding is

100 Overall Quality of Dampers to be improved. Regular checks at I
Vendors end must be ensured.

Stop Things- Dampers for LOCO

101 should not be despatched without
having "QC passed "sticker.

BASE LEVEL MEMBERS OF MFG & QC DEPT SHOULD

PLAN VISIT AT LEAST TWICE A YEAR TO DIFFERENT
102 CUSTOMERS OF ALL ZONES TO UNDERSTAND AND Suggestions
SHARE THE FIELD LEVEL DIFFICULTIES FACED BY
CUSTOMERS DUE TO QUALITY ISSUES.

WE NEED TO INTRODUCE TRAINING PROGRAMME FOR

103 WORKERS FOR EFFECTIVE AWARENESS REGARDING THE Suggestions
IMPORTANCE OF QUALITY.

REGULAR VISITS OF SERVICE ENGINEERS OF DIFFERENT

104 ZONES TO PLANT FOR RANDOM CHECKS OF QUALITY Suggestions
FOR DIFFERENT ITEMS
Design/Prod
105 Prodcut in accordnace with relevant EN uction Start things

106 EN Certification for Welding is must Process Start things

Production/P
107 Adherance to Drg and Product & process specification Start things
rocess
Production/P
108 Adherance to Quality plan/control Plan Start things
rocess

008000 Classification | ESCORTS-INTERNAL

 Quality/prod
109 Adherance to specificed Quality wall/QC process Start things
uction
110 Start Self certification Production Start things
Transfer to knowledge at workmen level for self Quality/prod
111 certification uction Start things

112 Adherance of SQA process for improvement of supplier SQA

Start Customer Loyality Program by measuring customer

feedback through NPS [NET PROMOTER SCORE].
Feedbacks may be taken after the completion of a
transaction, e.g., on completion of supplies of a PO, on
113 FES Start Things
supply performance and field quality. Also, after
attending a service job (warranty case or any other),
Service feedback may be collected through a
standardised format.

Attach atleast one customer oriented behavioral target

to each employee, like no, of feedbacks to be collected
114 from customer , and any value added activity done HR Start Things
which helps in enhancing the customer loyality (both
internal and external customer)

Review quality related training program needed by our

organisation in all functions esp. Quality & Production to Qulaity ,
115 be benchmarked with the best in industry / world class, Production , Start Things
which shall enhance the set goals of achiving overall Service
customer experience of a quality orgnanization

Measure revenue saved (top & bottom line) by

launching quality improvement programs, in terms of
116 Finance Start Things
reduction in wrong supply , short supply, warranty
replacement against product failure.

Launch customer interface app/ link on Escorts website ,

which provides the status of customers' Orders ,
warranty, technical support, any other useful
information in automted and self-service mode.
By using such
services , customer can log on to Escorts portal anytime ,
from anywhere and have a status of its Orders or any
query in a visual manner(like AMAZON/ZOMATO
IT & All
117 sites,etc. using which he gets instant input on his queries Start Things
functions
and feels delighted due to an overall enhanced
experience of Escorts Products and Services .Also, this
will help internal in Escorts in getting instant input that
at what stage and from how many hours/days, the
execution of any PO is pending, so that necessary action
may be taken to prevent , whether related to material
planning or production machine availability or
manpower .

Suitable Computer assisted Manufacturing softwares

may be adopted to optimise the manpower, machinery,
118 raw material to produce at the required pace with Production Start Things
quality. This will assist the manual planning being done
currently

Awareness to be created in the production people

working on the line to have the understanding of
119 importance of product. Resonsibility should come Production Start Things
within themselve for the importance of component they
are producing

008000 Classification | ESCORTS-INTERNAL

 Set up for product functioning to be made available.
This will help in checking actual issues (if any) prior to
120 dispatch. Testing can be done on random basis for any Quality Start Things
batch.

People to be educated for product knowledge and

121 functioning of components to understand the impact of All Start Things
any component during operation.

Requirement of training centre for all new joinees at

122 RED with dedicated instructor and Manuals availability Service/HR Start Things
for each product/component

Updated drawings of each parts (including child parts)

Design /
123 should be available with purchase department to avoid
Purchase
deviation from required SOS.
124 100 % inspection of each item at receipt end Quality
125 Zero deviation in respect to drawing. Quality
Proper product knowledge (including machining,
126 assembly, testing etc.) at shop floor to every workers / Production
suprevisors / Managers.
More skilled manpower should be available in 2nd/ 3rd
127 Production
shifts
Astectic look of products should be improved to Purchase /
128
compete with international quality standard. production
Full arrangement of testing facilities including all Quality /
129
required test benches for all products production
Improve the quality of painting, welding and inhouse Quality /
130
manufacturing products. production
131 No deviations QA Head Stop
Sr.
132 Autonomous SQA dep't Managemen Start
t

Sr.
133 Strong "Method's Dep't" Managemen Start
t
134 Internal customer should be taken seriously All Dep't Start
Fast execution of Capex projects related with Quality
135 All Dep't Start
issues / improvements
136 Strong skill development and verification system Production Start
137 Guage R&R as system QA Head Start
138 Machines capabilities Production Start
QA&Producti
139 Thorough "Shop petrolling check sheets" Start
on
Surface finish of castings should be better for good paint
140 Purchase Start
aesthetics
Proper CAPA for quality issues & horizontal deployment
141 Plant level Start
of same
142 Proper coordination between RI & Process QA QA Head Start
143 Start "Quality circles" across plant level Plant level Start
144 Celebrate "Quality Month" atleast once a year Plant level Start
145 Self certification for quality by Operator Production Start
Production Norms/Shift should be based on "Ok pcs
146 Production Start
manufacturing" only
147 "4 M change register" concept across the plant All Dep't Start

What ever material which is cleared from RQI should

not have any quality issues . Rotation / inter change of
148 QA Expectation
line quality team with RQI to imrove / better exchnage
of info to control defectes

008000 Classification | ESCORTS-INTERNAL

 Heavy materials like AARH main body , BMBS beams
149 shall be inspected at supplier premises and to be QA Expectation
supplied, to avoid time delay and Quality issues .

Rubber items shelf life to be checked by QA while time

of receipt and same quarter material is expected in QA &
150 Expectation
same month . Month and year of supply details to be Purchase
available on all rubber material on the packing .

151 Avoid excess material . Material flow must be in sets . Purchase Expectation

In ward Material packing requirement to be finalized

152 Purchase Expectation
and Material to be arranged accordingly
Rejection lifting to be handled / followed by Purchase
153 Purchase Expectation
team after RTV .

Casting quality to be improved .Penalty to casting

suppliers for casting defects - Any casting ,if defect
found after machining ,machining changes and other
154 involved material charges to be debited supplier .Penalty Purchase Expectation
to casting suppliers for casting defects - Any casting ,if
defect found after machining ,machining changes and
other involved material charges to be debited supplier .

Penalty to casting suppliers for casting defects - Any

casting ,if defect found after machining ,machining QA&Purchas
155 To start
charges and other involved material charges to be e
debited to casting supplier .

Firm plan for 3 months required from Marketing BY

156 15TH of every month to provide proper lead time for Marketing Expectation
Purchase .
157 Location based Storage with FIFO. Stores To start

TPI to inspect / audit both dimensional and Functional

158 TPI To start
parameters before RDSO / RITES inspection .

Final product packing - To cover with plastic covers

159 Logistics To start
before wooden packing
Storage - Avoid metal to metal contact .Storage in
160 PE & Stores To start
specific designed bins / pallets - Item wise
Aesthetic look of products should be improved to
161 Design/R&D
compete with "bench mark "standard
Skill level improvement training for all Executive - Like
162 HR
SPC- Design of experiment
Separate storage system for Liquid resin with reaction Purchase /
163
kettle ( stirrer ) production
Separate preservation storage for Brake Pad product Purchase /
164 and resin storage production
Finsihed good storage and "offered material" stacking
165 area to be Provided Production

Purchase /
166 New Mould and fixture for Brake Pad- Project production
Purchase /
167 K coach insert removal m/c -5 nos
production

Sample Lot to be saved for verifying till the whole lot is

168
conssumed at Assembly line - to revisit rejection.

169 List of Items to be checked before Despatches

170 Ensuring Packing list
Guarantee if item from vendor should be back to back
171 with customer

008000 Classification | ESCORTS-INTERNAL

 Paint removes during component handling at in-house
and transit:
172 Start the buffing operation before painting.

173 Use Non-metallic bins for transit of materials.

For dispatch outside, boxes should have different

174
cabins / slots inside the box to hold different materials.

CTQ ( Control to Quality) dimensions/parameters to be

175 identified and incorporated in check sheets involve CFT
team
Ensure Benchmark product test details availability with
176
line testing team.

The testing rigs should be periodically validated for

correctness & should be validated by authorised person.
177

178 Stop buying rubber parts from local suppliers

179 To have expertise team in Quality group to check Electronics parts
To have proper controlled storage:
180 Need to establish proper store with ESD and
environmental compliance.

Field failure feedbacks to be followed up and closed

properly :
181
use proper tool to record fee backs & improve reliability
of the products
182 Drawing deviations to be highlighted and discussed for manufacturing feasibility
183 Drawing revision mis-matches at purchase and the supplier to be corrected
Welding quality improvement:
184 Welding quality certification as per EN-15085-2 to be
implemented

In-process Quality Improvement:

185 Patrol inspection to be executed to monitor the quality
of product (at sub-assembly / assembly level).

Critical Assembly process:

Process-wise Minimum skill level of operator to be
186
defined.
-Avoid frequent change of man power

Process improvement: Tooling life to be defined for all

187
special process.
188 In-process Quality Improvement: First piece approval for special process to be established

Damper Performance improvement:

1) 100% inspection for critical parameters (Piston, Valve
189 plate, Cylinder bottom etc).
2) Start 100% inspection of cylinder through mandrel (to
verify the straightness & roundness).

To have Ac storage for critical chemical like solid resin,

190
liquid resin, Hot SBR , hexamine, sulpher etc.

Solid Resin- Inspection: Free from phenol (to be

191
checked from outside lab)
Liquid resin - Inspection: Moisture content to be
192
checked from outside lab

Moisture content & bulk density of each mix to be

193 checked & to be kept at dehumidified area (Closed
storage with specified temperature & humidity)
Strict adherance on process parameter:
Brake block pressing as per specified pressing parameter
194
like degasing cycle, pressure &
cycle time

008000 Classification | ESCORTS-INTERNAL

 RAW MATERIAL WEIGHMENT FOR COMPOUND : To
maintain the defined accuracy of ratio of different
195 chemicals & avoid missing to add some ingradient, use
automatic weighing system.

MIXING CONTROL : At present there is no control over

compound mix and dispersion , causes much variation in
196
same mix batch. Use Moony viscometer & Dispersion
analyzer

CONTROL OVER MOULDING : In compression moulding

there is no control over time and temperature except
digital display, there is a possiblity for quality deviation
in night shift for demoulding the product before
197
prescribed time or increases temperature and reduce
the time for curing.
Attach Time Vs. Temperature recorder device directly
with mould

STORAGE OF RAW MATERIAL AND MIX BATCHES : To

198 have temperature/moisture/humidity controled storage
room

008000 Classification | ESCORTS-INTERNAL

Review Dt 7th
Jan20

Project Name

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1

5
5

4
0

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4

1
6

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4

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4

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4

4
4

1
4
1

4
4
4
1

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5

9
9

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1

7
4

4
7

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1

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