Month Total Rejn % Prod Parts Rej %

April 7.5 7.38

14
May 9.8 8.7
June 11.02 9.97 12
July 10.28 9.43 12
11.02
August 12.26 10.5 10.28
September 11.91 10.4 9.8
10 10
October 12.41 10.52 9.97
9.43
8 7.5 8.7

7.38
6

0
April May June July Au
 12.26 12.41
11.91
11.02
10.28
9.8
10.5 10.4 10.52
9.97
9.43
8.7
Total Rejn %
Prod Parts Rej %

May June July August September October

 Top 5 production parts by total rejection (Quantity)
Sr No Part Name Weight (kg) Fdy Rejn Qty M/C Rejn Qty Total Qty

1 3DU 5.37 1054 2937 3991

2 NGCR BODY 6.02 689 246 935

3 HUB OPNER 2.72 292 546 838

4 CR 22 BODY 6.92 215 162 377

5 TACO 6890 10.74 152 165 317

SR NO.PART NAME PART WT. PRODN QTY PRODN WT. TOTAL REJN QTY
2 3DU 5.365 27372 146850.78 3991
4 NGCR BODY 6.017 12000 72204.00 935
12 HUB OPNER 2.721 10328 28102.49 838
1 CR 22 BODY 6.92 3546 24538.32 377
5 TACO 6890 10.736 2848 30576.13 317
21 SPINDLE-CE70 2.96 0 0.00 278
8 KCJ BODY SMA 4.993 648 3235.46 261
39 KCJ BODY BIG 4.857 3672 17834.90 254
3 875 CARRIER 25.473 26 662.30 212
15 TG CASE 302 18.88 837 15802.56 197
11 COVER CARRIE 9.33 912 8508.96 190
14 SIDE HOUSING 12.604 1321 16649.88 188
9 DIPL COVER 17.908 4158 74461.46 170
42 BRAKE PISTON- 5.635 2984 16814.84 168
10 SIDE HOUSING 12.573 1321 16608.93 166
26 Brake piston 5.275 1854 9779.85 166
23 ROCKSHAFT 21 10.522 1467 15435.77 161
6 OIL PAN 21.96 2231 48992.76 146
7 SPINDLE 714 21.105 2214 46726.47 139
13 SIDE HOUSING 14.08 484 6814.72 139
19 SIDE HOUSING 14.037 484 6793.91 110
18 JD COVER 344 8.582 2202 18897.56 100
16 Hub Housing 8.656 1209 10465.10 85
38 HOUSING D60 9.825 1260 12379.50 64
32 HOUSING-CE6 7.272 660 4799.52 61
33 SPINDLE 716 20.775 538 11176.95 56
43 piston 902425 2.378 2152 5117.46 53
36 HSG 602 9.755 0 0.00 52
49 BEARING CAP 1.45 300 435.00 47
29 BRACKET 363 13.9 218 3030.20 46
34 SPRING HOUSI 4.715 738 3479.67 42
58 HUB 569 7.221 1920 13864.32 41
30 Hub 950 31.11 262 8150.82 37
47 DRUM 738 12.11 480 5812.80 37
22 HOUSING 626 25.62 412 10555.44 36
27 TACO 8068 9.497 0 0.00 35
35 FINAL CASE 11.297 670 7568.99 34
45 CARRIER 9260 11.26 864 9728.64 34
40 BRACKET 763 13.74 266 3654.84 30
25 BRAKE COVER 8.92 0 0.00 26
20 HOUSING 643 27.43 236 6473.48 24
65 Basic Housing- 12.84 100 1284.00 24
50 DRUM 748 JD 3.95 426 1682.70 23
28 housing NO601 27.887 457 12744.36 22
37 SPINDLE 728 21.145 646 13659.67 22
51 WHEEL HUB 10 12.24 0 0.00 22
53 DIFF CASE MON 8.545 1084 9262.78 18
17 HUB 640 45.9 0 0.00 17
24 CONNECT COVE 23.445 129 3024.41 17
48 ARM SPRING B 10.255 494 5065.97 15
31 HOUSING 603 28.21 406 11453.26 11
62 IAD COVER 46 6.23 0 0.00 10
46 FRONT MOUNT 12.01 0 0.00 6
64 Basic Housing- 6.31 228 1438.68 4
41 BKT 719 28.033 94 2635.10 3
44 SPINDLE 731 19.61 0 0.00 3
52 JD SHANK BRA 8.41 0 0.00 1
54 BRACKET 277 9.05 0 0.00 0
55 PLANE DIFF CA 12.12 0 0.00 0
56 BRACKET RH(1 26.4 0 0.00 0
57 bracket 278 9.64 0 0.00 0
59 BKT 619 28.323 0 0.00 0
60 BRACKET LH(14 26.8 0 0.00 0
61 HUB 656 4.9 0 0.00 0
63 450 CARRIER 37.5 0 0.00 0
ection (Quantity)
Rejection Weight (kg) Top Defects

Slag
21411.715 BH
Shrinkage
Core Inclusion

Fett Damage
5625.895 Excess Fett
Short Pour
Sand Inclusion

Blow Hole (304)

2280.198 Excess Fett (192)
Slag (156)
Shrinkage (63)

Slag (74)
2608.84 Core shift (47)
Fett Damage (41)
Sand Drop & Blow hole (each 30)

Blow Hole (151)

3403.312 Sand drop (47)
Slag (21)
Core Inclusion (20)

REJN % TOTAL REJN WT. FDY REJ QTY FDY REJ WT

14.58 21411.72 1054 5654.71
7.79 5625.90 689 4145.71
8.11 2280.20 292 794.53
10.63 2608.84 215 1487.80
11.13 3403.31 152 1631.87
#DIV/0! 822.88 11 32.56
40.28 1303.17 58 289.59
6.92 1233.68 184 893.69
815.38 5400.28 5 127.37
23.54 3719.36 77 1453.76
20.83 1772.70 69 643.77
14.23 2369.55 51 642.80
4.09 3044.36 76 1361.01
5.63 946.68 73 411.35
12.57 2087.12 57 716.66
8.95 875.65 80 422.00
10.97 1694.04 54 568.19
6.54 3206.16 105 2305.80
6.28 2933.60 39 823.10
28.72 1957.12 64 901.12
22.73 1544.07 37 519.37
4.54 858.20 63 540.67
 7.03 735.76 11 95.22
5.08 628.80 37 363.53
9.24 443.59 20 145.44
10.41 1163.40 22 457.05
2.46 126.03 5 11.89
#DIV/0! 507.26 12 117.06
15.67 68.15 39 56.55
21.10 639.40 30 417.00
5.69 198.03 27 127.30
2.14 296.06 7 50.55
14.12 1151.07 9 279.99
7.71 448.07 11 133.21
8.74 922.32 24 614.88
#DIV/0! 332.40 0 0.00
5.07 384.10 28 316.32
3.94 382.84 34 382.84
11.28 412.20 23 316.02
#DIV/0! 231.92 0 0.00
10.17 658.32 6 164.58
24.00 308.16 24 308.16
5.40 90.85 1 3.95
4.81 613.51 1 27.89
3.41 465.19 10 211.45
#DIV/0! 269.28 0 0.00
1.66 153.81 9 76.91
#DIV/0! 780.30 0 0.00
13.18 398.57 2 46.89
3.04 153.83 15 153.83
2.71 310.31 7 197.47
#DIV/0! 62.30 10 62.30
#DIV/0! 72.06 1 12.01
1.75 25.24 4 25.24
3.19 84.10 2 56.07
#DIV/0! 58.83 0 0.00
#DIV/0! 8.41 0 0.00
#DIV/0! 0.00 0 0.00
#DIV/0! 0.00 0 0.00
#DIV/0! 0.00 0 0.00
#DIV/0! 0.00 0 0.00
#DIV/0! 0.00 0 0.00
#DIV/0! 0.00 0 0.00
#DIV/0! 0.00 0 0.00
#DIV/0! 0.00 0 0.00
 Top 5 Dev
Sr No

FR REJ % M/C REJ QTY M/C REJ WT CR REJ %

3.85 2937 15757.01 10.73
5.74 246 1480.18 2.05
2.83 546 1485.67 5.29
6.06 162 1121.04 4.57
5.34 165 1771.44 5.79
#DIV/0! 267 790.32 #DIV/0!
8.95 203 1013.58 31.33
5.01 70 339.99 1.91
19.23 207 5272.91 796.15
9.20 120 2265.60 14.34
7.57 121 1128.93 13.27
3.86 137 1726.75 10.37
1.83 94 1683.35 2.26
2.45 95 535.32 3.18
4.31 109 1370.46 8.25
4.31 86 453.65 4.64
3.68 107 1125.85 7.29
4.71 41 900.36 1.84
1.76 100 2110.50 4.52
13.22 75 1056.00 15.50
7.64 73 1024.70 15.08
2.86 37 317.53 1.68
 0.91 74 640.54 6.12
2.94 27 265.28 2.14
3.03 41 298.15 6.21
4.09 34 706.35 6.32
0.23 48 114.14 2.23
#DIV/0! 40 390.20 #DIV/0!
13.00 8 11.60 2.67
13.76 16 222.40 7.34
3.66 15 70.73 2.03
0.36 34 245.51 1.77
3.44 28 871.08 10.69
2.29 26 314.86 5.42
5.83 12 307.44 2.91
#DIV/0! 35 332.40 #DIV/0!
4.18 6 67.78 0.90
3.94 0 0.00 0.00
8.65 7 96.18 2.63
#DIV/0! 26 231.92 #DIV/0!
2.54 18 493.74 7.63
24.00 0 0.00 0.00
0.23 22 86.90 5.16
0.22 21 585.63 4.60
1.55 12 253.74 1.86
#DIV/0! 22 269.28 #DIV/0!
0.83 9 76.91 0.83
#DIV/0! 17 780.30 #DIV/0!
1.55 15 351.68 11.63
3.04 0 0.00 0.00
1.72 4 112.84 0.99
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 5 60.05 #DIV/0!
1.75 0 0.00 0.00
2.13 1 28.03 1.06
#DIV/0! 3 58.83 #DIV/0!
#DIV/0! 1 8.41 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
 Top 5 Development parts by total rejection (Quantity)
Part Name Weight (kgFdy Rejn QM/C Rejn Total Qty Rejection

CHAINA CARRIER 3.5 46 410 456 1596

510 CARRIER 6.49 57 233 290 1882.1

taco v3 8390 14.524 83 163 246 3572.904

PADAMINI 147200100 5.65 98 140 238 1344.7

LUV CARRIER 23498 5.613 127 61 188 1055.244

Quantity)
Top Defects

Shrinkage-330
Casting shift-56
Pin Hole-17

BH-191
Less wall-33
Box Leak-28

BH-165
Cold-18

BH-98
Sand drop-45
Core inclusion-29

Slag-69
BH & Excess Fett-each 23
Fett damage-20
Sand drop-17
 Top 10
SR NO. PART NAME PART WT. PRODN QTY PRODN WT.

1 3DU 5.365 27372 146850.78

2 NGCR BODY 6.017 12000 72204.00

3 875 CARRIER 25.473 26 662.30

4 TG CASE 302 18.88 837 15802.56

5 TACO 6890 10.736 2848 30576.13

6 OIL PAN 21.96 2231 48992.76

7 DIPL COVER 17.908 4158 74461.46
8 SPINDLE 714 21.105 2214 46726.47
9 CR 22 BODY 6.92 3546 24538.32
10 SIDE HOUSING LH (83) NEW 12.604 1321 16649.88

SR NO. PART NAME PART WT. PRODN QTY PRODN WT.

2 3DU 5.365 27372 146850.78
4 NGCR BODY 6.017 12000 72204.00
3 875 CARRIER 25.473 26 662.30
15 TG CASE 302 18.88 837 15802.56
5 TACO 6890 10.736 2848 30576.13
6 OIL PAN 21.96 2231 48992.76
9 DIPL COVER 17.908 4158 74461.46
7 SPINDLE 714 21.105 2214 46726.47
1 CR 22 BODY 6.92 3546 24538.32
14 SIDE HOUSING LH (83) NEW 12.604 1321 16649.88
12 HUB OPNER 2.721 10328 28102.49
10 SIDE HOUSING RH (84) NEW 12.573 1321 16608.93
13 SIDE HOUSING LH 8006 14.08 484 6814.72
11 COVER CARRIER 131220 9.33 912 8508.96
23 ROCKSHAFT 2154 10.522 1467 15435.77
19 SIDE HOUSING RH 8011 14.037 484 6793.91
8 KCJ BODY SMALL BORE 4.993 648 3235.46
39 KCJ BODY BIG BORE 4.857 3672 17834.90
33 SPINDLE 716 20.775 538 11176.95
30 Hub 950 31.11 262 8150.82
42 BRAKE PISTON- 62.9 212 5.635 2984 16814.84
22 HOUSING 626 25.62 412 10555.44
26 Brake piston 902497 5.275 1854 9779.85
18 JD COVER 344 8.582 2202 18897.56
21 SPINDLE-CE701 2.96 0 0.00
17 HUB 640 45.9 0 0.00
16 Hub Housing 5797V1 (MAHINDRA) 8.656 1209 10465.10
20 HOUSING 643 27.43 236 6473.48
29 BRACKET 363 13.9 218 3030.20
38 HOUSING D601 9.825 1260 12379.50
28 housing NO601 27.887 457 12744.36
36 HSG 602 9.755 0 0.00
37 SPINDLE 728 21.145 646 13659.67
47 DRUM 738 12.11 480 5812.80
32 HOUSING-CE601 7.272 660 4799.52
40 BRACKET 763 13.74 266 3654.84
24 CONNECT COVER 1925 23.445 129 3024.41
35 FINAL CASE 11.297 670 7568.99
45 CARRIER 9260 11.26 864 9728.64
27 TACO 8068 9.497 0 0.00
31 HOUSING 603 28.21 406 11453.26
65 Basic Housing- X726 12.84 100 1284.00
58 HUB 569 7.221 1920 13864.32
51 WHEEL HUB 10120418 12.24 0 0.00
25 BRAKE COVER 442 8.92 0 0.00
34 SPRING HOUSING 902493 4.715 738 3479.67
48 ARM SPRING BRACKET KK22964 10.255 494 5065.97
53 DIFF CASE MONO 111.04.56.61.9 8.545 1084 9262.78
43 piston 902425 2.378 2152 5117.46
50 DRUM 748 JD 3.95 426 1682.70
41 BKT 719 28.033 94 2635.10
46 FRONT MOUNT 6471 12.01 0 0.00
49 BEARING CAP 428 1.45 300 435.00
62 IAD COVER 4619 6.23 0 0.00
44 SPINDLE 731 19.61 0 0.00
64 Basic Housing- CX718 6.31 228 1438.68
52 JD SHANK BRACKET 461 8.41 0 0.00
54 BRACKET 277 9.05 0 0.00
55 PLANE DIFF CASE 4632 12.12 0 0.00
56 BRACKET RH(1390) 26.4 0 0.00
57 bracket 278 9.64 0 0.00
59 BKT 619 28.323 0 0.00
60 BRACKET LH(1400) 26.8 0 0.00
61 HUB 656 4.9 0 0.00
63 450 CARRIER 37.5 0 0.00
99158 805235.725
SR NO. PART NAME PART WT. PRODN QTY PRODN WT.
Top 10 production parts by total rejection (weight)
TOTAL REJN QTY REJN % TOTAL REJN WT. FDY REJ QTY FDY REJ WT

3991 14.58 21.41 1054 5654.71

935 7.79 5.63 689 4145.71

212 815.38 5.40 5 127.37

197 23.54 3.72 77 1453.76

317 11.13 3.40 152 1631.87

146 6.54 3.21 105 2305.80

170 4.09 3.04 76 1361.01
139 6.28 2.93 39 823.10
377 10.63 2.61 215 1487.80
188 14.23 2.37 51 642.80

TOTAL REJN QTY REJN % TOTAL REJN WT. FDY REJ QTY FDY REJ WT
3991 14.58 21.41 1054 5654.71
935 7.79 5.63 689 4145.71
212 815.38 5.40 5 127.37
197 23.54 3.72 77 1453.76
317 11.13 3.40 152 1631.87
146 6.54 3.21 105 2305.80
170 4.09 3.04 76 1361.01
139 6.28 2.93 39 823.10
377 10.63 2.61 215 1487.80
188 14.23 2.37 51 642.80
838 8.11 2.28 292 794.53
166 12.57 2.09 57 716.66
139 28.72 1.96 64 901.12
190 20.83 1.77 69 643.77
161 10.97 1.69 54 568.19
110 22.73 1.54 37 519.37
261 40.28 1.30 58 289.59
254 6.92 1.23 184 893.69
 56 10.41 1.16 22 457.05
37 14.12 1.15 9 279.99
168 5.63 0.95 73 411.35
36 8.74 0.92 24 614.88
166 8.95 0.88 80 422.00
100 4.54 0.86 63 540.67
278 #DIV/0! 0.82 11 32.56
17 #DIV/0! 0.78 0 0.00
85 7.03 0.74 11 95.22
24 10.17 0.66 6 164.58
46 21.10 0.64 30 417.00
64 5.08 0.63 37 363.53
22 4.81 0.61 1 27.89
52 #DIV/0! 0.51 12 117.06
22 3.41 0.47 10 211.45
37 7.71 0.45 11 133.21
61 9.24 0.44 20 145.44
30 11.28 0.41 23 316.02
17 13.18 0.40 2 46.89
34 5.07 0.38 28 316.32
34 3.94 0.38 34 382.84
35 #DIV/0! 0.33 0 0.00
11 2.71 0.31 7 197.47
24 24.00 0.31 24 308.16
41 2.14 0.30 7 50.55
22 #DIV/0! 0.27 0 0.00
26 #DIV/0! 0.23 0 0.00
42 5.69 0.20 27 127.30
15 3.04 0.15 15 153.83
18 1.66 0.15 9 76.91
53 2.46 0.13 5 11.89
23 5.40 0.09 1 3.95
3 3.19 0.08 2 56.07
6 #DIV/0! 0.07 1 12.01
47 15.67 0.07 39 56.55
10 #DIV/0! 0.06 10 62.30
3 #DIV/0! 0.06 0 0.00
4 1.75 0.03 4 25.24
1 #DIV/0! 0.01 0 0.00
0 #DIV/0! 0.00 0 0.00
0 #DIV/0! 0.00 0 0.00
0 #DIV/0! 0.00 0 0.00
0 #DIV/0! 0.00 0 0.00
0 #DIV/0! 0.00 0 0.00
0 #DIV/0! 0.00 0 0.00
0 #DIV/0! 0.00 0 0.00
0 #DIV/0! 0.00 0 0.00
10561 10.65 0.00 3936 31599.002
TOTAL REJN QTY REJN % #VALUE! FDY REJ QTY FDY REJ WT
FR REJ % M/C REJ QTY M/C REJ WT CR REJ %

Slag
3.85 2937 15757.01 10.73 BH
Shrinkage
Core Inclusion

Fett Damage
5.74 246 1480.18 2.05 Excess Fett
Short Pour
Sand Inclusion

19.23 207 5272.91 796.15

Shrinkage (192)
Blow hole (9)

BH (70)
9.20 120 2265.60 14.34 Shrinkage (24)
Core Incl (24)
Core shift (19)

Blow Hole (151)

5.34 165 1771.44 5.79 Sand drop (47)
Slag (21)
Core Inclusion (20)
4.71 41 900.36 1.84
1.83 94 1683.35 2.26
1.76 100 2110.50 4.52
6.06 162 1121.04 4.57
3.86 137 1726.75 10.37

FR REJ % M/C REJ QTY M/C REJ WT CR REJ %

3.85 2937 15757.01 10.73
5.74 246 1480.18 2.05
19.23 207 5272.91 796.15
9.20 120 2265.60 14.34
5.34 165 1771.44 5.79
4.71 41 900.36 1.84
1.83 94 1683.35 2.26
1.76 100 2110.50 4.52
6.06 162 1121.04 4.57
3.86 137 1726.75 10.37
2.83 546 1485.67 5.29
4.31 109 1370.46 8.25
13.22 75 1056.00 15.50
7.57 121 1128.93 13.27
3.68 107 1125.85 7.29
7.64 73 1024.70 15.08
8.95 203 1013.58 31.33
5.01 70 339.99 1.91
 4.09 34 706.35 6.32
3.44 28 871.08 10.69
2.45 95 535.32 3.18
5.83 12 307.44 2.91
4.31 86 453.65 4.64
2.86 37 317.53 1.68
#DIV/0! 267 790.32 #DIV/0!
#DIV/0! 17 780.30 #DIV/0!
0.91 74 640.54 6.12
2.54 18 493.74 7.63
13.76 16 222.40 7.34
2.94 27 265.28 2.14
0.22 21 585.63 4.60
#DIV/0! 40 390.20 #DIV/0!
1.55 12 253.74 1.86
2.29 26 314.86 5.42
3.03 41 298.15 6.21
8.65 7 96.18 2.63
1.55 15 351.68 11.63
4.18 6 67.78 0.90
3.94 0 0.00 0.00
#DIV/0! 35 332.40 #DIV/0!
1.72 4 112.84 0.99
24.00 0 0.00 0.00
0.36 34 245.51 1.77
#DIV/0! 22 269.28 #DIV/0!
#DIV/0! 26 231.92 #DIV/0!
3.66 15 70.73 2.03
3.04 0 0.00 0.00
0.83 9 76.91 0.83
0.23 48 114.14 2.23
0.23 22 86.90 5.16
2.13 1 28.03 1.06
#DIV/0! 5 60.05 #DIV/0!
13.00 8 11.60 2.67
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 3 58.83 #DIV/0!
1.75 0 0.00 0.00
#DIV/0! 1 8.41 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
#DIV/0! 0 0.00 #DIV/0!
3.92 6625 53084.035 6.59
FR REJ % M/C REJ QTY M/C REJ WT CR REJ %
SR NO. PART NAME PART WT. PRODN QTY

1 SPINDLE 705 (CTL) 42.07 306

2 taco v3 8390 14.524 1784

3 knuckle 2673 18.667 448

4 STEERING HUB 2667 18.637 384

5 HOUSING 1001 16.612 611

6 HOUSING 2001 20.74 147

7 510 CARRIER 6.49 1369
8 CHAINA CARRIER 3.5 774
9 PADAMINI 147200100 5.65 1639
10 PLAIN DIFF CASE 9818 10.017 84

SR NO. PART NAME PART WT. PRODN QTY

2 SPINDLE 705 (CTL) 42.07 306
8 taco v3 8390 14.524 1784
10 knuckle 2673 18.667 448
5 STEERING HUB 2667 18.637 384
27 HOUSING 1001 16.612 611
19 HOUSING 2001 20.74 147
1 510 CARRIER 6.49 1369
7 CHAINA CARRIER 3.5 774
13 PADAMINI 147200100 5.65 1639
22 PLAIN DIFF CASE 9818 10.017 84
6 LUV CARRIER 23498 5.613 1506
21 CARRIER 509 6.66 1369
32 HUB 2442 32.01 43
12 503 carrier 4.055 1179
40 Bracket 820 LH 9.61 483
42 Bracket 1120 RH 9.58 489
23 AXEL CASE LH 006517655L11 23.83 51
20 ADAPTER D2401410 13.57 0
36 NORD 4282 36.62 142
3 drop box-21930 10.45 762
9 SWASH PLATE 749 4.59 935
24 AXEL CASE RH 7683L11 24.22 21
33 TOCO 8078 10.77 16
28 NORD 2282 11.015 155
18 CASE GEAR LH6522752 8.75 0
4 SWASH PLATE 794 3.45 960
15 CASE GEAR RH 6522753 8.85 0
41 FLANGE DIFF CARRIER FORK-9897 16.817 268
37 CTL 641 37.96 0
31 SPACER DRAW BAR-2097 2.5 704
25 HOUSING-CE602 6.01 208
29 DIFF CASE 4610 3.77 712
17 KUPPL-NABE 2670 682.0 9.59 391
39 Case king pin 748 6.17 0
45 DIFF CASE HOUSING 112 7.23 72
38 CARRIER 502 5.1 0
26 KUPPL- STUECK 2670 692.1 2.9 43
14 SHIPPING STEERING STOP-9860 2.25 864
11 BREAK CALIPER COVER 102 2.87 60
44 DIFF 549 2.61 0
16 CENTRAL HOUSING 303 45.34 0
30 LEFT STEARING HUB 6419 19.26 0
34 HUB DRIVE AXLE-FD 300 20.35 0
35 COMMER HOUSING 301 35.58 0
43 CARRIER-5957/962 4.02 148
46 Carrier - D2210517 2.44 256
 Top 10 Development parts by total rejection (weight)
PRODN WT. TOTAL REJN QTY REJN % TOTAL REJN WT.

12873.42 173 56.54 7278.11

25910.82 246 13.79 3572.90

8362.82 150 33.48 2800.05

7156.61 124 32.29 2310.99

10149.93 131 21.44 2176.17

3048.78 99 67.35 2053.26

8884.81 290 21.18 1882.10
2709.00 456 58.91 1596.00
9260.35 238 14.52 1344.70
841.43 129 153.57 1292.19

PRODN WT. TOTAL REJN QTY REJN % TOTAL REJN WT.

12873.42 173 56.54 7278.11
25910.82 246 13.79 3572.90
8362.82 150 33.48 2800.05
7156.61 124 32.29 2310.99
10149.93 131 21.44 2176.17
3048.78 99 67.35 2053.26
8884.81 290 21.18 1882.10
2709.00 456 58.91 1596.00
9260.35 238 14.52 1344.70
841.43 129 153.57 1292.19
8453.18 188 12.48 1055.24
9117.54 141 10.30 939.06
1376.43 25 58.14 800.25
4780.84 188 15.95 762.34
4641.63 64 13.25 615.04
4684.62 64 13.09 613.12
1215.33 24 47.06 571.92
0.00 38 #DIV/0! 515.66
5200.04 14 9.86 512.68
7962.90 39 5.12 407.55
4291.65 73 7.81 335.07
508.62 11 52.38 266.42
172.32 23 143.75 247.71
1707.33 22 14.19 242.33
0.00 25 #DIV/0! 218.75
3312.00 61 6.35 210.45
0.00 23 #DIV/0! 203.55
4506.96 10 3.73 168.17
0.00 4 #DIV/0! 151.84
1760.00 59 8.38 147.50
1250.08 22 10.58 132.22
2684.24 13 1.83 49.01
3749.69 5 1.28 47.95
0.00 6 #DIV/0! 37.02
520.56 5 6.94 36.15
0.00 6 #DIV/0! 30.60
124.70 3 6.98 8.70
1944.00 3 0.35 6.75
172.20 2 3.33 5.74
0.00 2 #DIV/0! 5.22
0.00 0 #DIV/0! 0.00
0.00 0 #DIV/0! 0.00
0.00 0 #DIV/0! 0.00
0.00 0 #DIV/0! 0.00
594.96 0 0.00 0.00
624.64 0 0.00 0.00
ction (weight)
FDY REJ QTY FDY REJ WT FR REJ % M/C REJ QTY M/C REJ WT

94 3954.58 30.72 79 3323.53

83 1205.49 4.65 163 2367.41

20 373.34 4.46 130 2426.71

27 503.20 7.03 97 1807.79

36 598.03 5.89 95 1578.14

69 1431.06 46.94 30 622.20

57 369.93 4.16 233 1512.17
46 161.00 5.94 410 1435.00
98 553.70 5.98 140 791.00
31 310.53 36.90 98 981.67

FDY REJ QTY FDY REJ WT FR REJ % M/C REJ QTY M/C REJ WT
94 3954.58 30.72 79 3323.53
83 1205.49 4.65 163 2367.41
20 373.34 4.46 130 2426.71
27 503.20 7.03 97 1807.79
36 598.03 5.89 95 1578.14
69 1431.06 46.94 30 622.20
57 369.93 4.16 233 1512.17
46 161.00 5.94 410 1435.00
98 553.70 5.98 140 791.00
31 310.53 36.90 98 981.67
127 712.85 8.43 61 342.39
47 313.02 3.43 94 626.04
11 352.11 25.58 14 448.14
19 77.04 1.61 169 685.30
64 615.04 13.25 0 0.00
64 613.12 13.09 0 0.00
23 548.09 45.10 1 23.83
8 108.56 #DIV/0! 30 407.10
 6 219.72 4.23 8 292.96
28 292.60 3.67 11 114.95
25 114.75 2.67 48 220.32
11 266.42 52.38 0 0.00
7 75.39 43.75 16 172.32
20 220.30 12.90 2 22.03
19 166.25 #DIV/0! 6 52.50
16 55.20 1.67 45 155.25
18 159.30 #DIV/0! 5 44.25
8 134.54 2.99 2 33.63
4 151.84 #DIV/0! 0 0.00
59 147.50 8.38 0 0.00
4 24.04 1.92 18 108.18
10 37.70 1.40 3 11.31
0 0.00 0.00 5 47.95
3 18.51 #DIV/0! 3 18.51
5 36.15 6.94 0 0.00
1 5.10 #DIV/0! 5 25.50
3 8.70 6.98 0 0.00
3 6.75 0.35 0 0.00
2 5.74 3.33 0 0.00
2 5.22 #DIV/0! 0 0.00
0 0.00 #DIV/0! 0 0.00
0 0.00 #DIV/0! 0 0.00
0 0.00 #DIV/0! 0 0.00
0 0.00 #DIV/0! 0 0.00
0 0.00 0.00 0 0.00
0 0.00 0.00 0 0.00
CR REJ %

25.82 Shrinkage (132)

Slag-5
BH-5

9.14
BH-165
Cold-18

29.02

25.26

15.55 Shrinkage-43
BH-24
Box leak-17
20.41
17.02
52.97
8.54
116.67

CR REJ %
25.82
9.14
29.02
25.26
15.55
20.41
17.02
52.97
8.54
116.67
4.05
6.87
32.56
14.33
0.00
0.00
1.96
#DIV/0!
 5.63
1.44
5.13
0.00
100.00
1.29
#DIV/0!
4.69
#DIV/0!
0.75
#DIV/0!
0.00
8.65
0.42
1.28
#DIV/0!
0.00
#DIV/0!
0.00
0.00
0.00
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
0.00
0.00
 at Foundry stage at M
Sr No Defects name No. Of defectives Contributors Sr No

388- 3DU
110- Hub opener
1 SLAG 961 1
64- LUV CARRIER 23498
46-SPACER DRAW BAR-2097

168-NGCR body
100- KCJ Big bore
2 FETT, DAMAGE 602 2
84- 3DU
50- CR22 body

53-NGCR Body
51-Taco 6890
3 SAND DROP 550 3
45-PADMINI 147200100
41- Housing 2001

4 EXCESS FETTLING 460 4

5 CORE INCLUSION 427 5

6 SHRINKAGE 315 6

7 SHORT POUR 241 7

8 MOLD CRACK 235 8

9 BLOW HOLE 230 9

10 COLD 162 10

SAND INCLUSION 147

 at M/C stage Top 10 Defects (Foundr
Defects name No. Of defectives Contributors Sr No Defects name

997- 3DU
348- Hub Opener
BLOW HOLE 3062 1 BLOW HOLE
237- Spindle CE701
191- Carrier 510

329- Chiana Carrier

SHRINKAGE 1458 207- 3DU 2 SLAG
191- 875 Carrier

676- 3DU
SLAG 1343 68- CR22 3 SHRINKAGE
57- Rockshaft 2154

CORE INCLUSION 575 4 FETT, DAMAGE

EXCESS FETTLING 438 5 CORE INCLUSION

FETT, DAMAGE 403 6 EXCESS FETTLING

CORE SHIFT 275 7 SAND DROP

CASTING SHIFT 150 8 MOLD CRACK

PIN HOLE 132 9 CORE SHIFT

SAND INCLUSION 110 10 SAND INCLUSION

SHORT POUR
Top 10 Defects (Foundry + M/C)
No. Of defectives Contributors

1004- 3DU
350- Hub Opener
3292
237- Spindle CE701
191- Carrier 510

1064- 3DU Top 10 Defects (Foun

157- Hub Opener
2304
78- CR22 3500
72- Rockshaft 2154 3292

3000
330- Chiana Carrier
209- 3DU
1773
193- 875 Carrier 2500
73-SIDE HOUSING RH (84) NEW 2304

247-NGCR Body 2000

1773
1005 147- 3DU
103- KCJ Big bore
1500
742- 3DU
1002
63-COVER CARRIER 131220 1005 1002
1000 898
192- Hub Opener 616
898 121- NGCR Body
87- KCJ Small bore 500

60-NGCR Body
0
616 51-Taco 6890
45-PADMINI 147200100 LE AG
E E N G OP
HO SL K AG AG SIO
TLIN
DR
N M U T C
61-3DU OW HRI , DA NCL FE ND LD
BL S T T E I SS SA O
299 39- Bearing cap FE R CE M
37- Brake Piston 212 CO EX

48- CR22
288
42- 3DU
92- NGCR body
257
87- 3DU
252
Top 10 Defects (Foundry + M/C)

73
No. Of defectives

1005 1002
898
616

299 288 257

E
AG
N
IN
G OP AC
K FT N
M USIO
TL DR R SHI USIO
T C
DA CL E D E CL
T, E IN SSF SAN O LD COR IN
R CE M ND
CO EX SA
SR NO. PART WT. PRODN QTY PRODN WT. TOTAL REJN QTY REJN % PART NAME
1 5.365 27372 146850.78 3991 14.58 3DU
2 6.017 12000 72204.00 935 7.79 NGCR BODY
3 25.473 26 662.30 212 20.00 875 CARRIER
4 18.88 837 15802.56 197 23.54 TG CASE 302
5 10.736 2848 30576.13 317 11.13 TACO 6890
6 21.96 2231 48992.76 146 6.54 OIL PAN
7 17.908 4158 74461.46 170 4.09 DIPL COVER
8 21.105 2214 46726.47 139 6.28 SPINDLE 714
9 6.92 3546 24538.32 377 10.63 CR 22 BODY
10 12.604 1321 16649.88 188 14.23 SIDE HOUSING LH (83) NEW

TOTAL REJN WT.

25.00
21.41
20.00

15.00

10.00
5.63 5.40 TOTAL REJN WT.
5.00 3.72 3.40 3.21 3.04 2.93 2.61 2.37
0.00
U ER 2 0 AN R 14
3D DY RI 30 89 VE 7 DY NE
W
BO R E 6 LP O LE BO 3)
CR CA CA
S O OI LC D 22
5 AC DI
P IN (8
NG 8 7 TG T SP CR LH
G
SIN
U
E HO
SID
 TOTAL REJN WT. FDY REJ QTY FDY REJ WT FR REJ % M/C REJ QTY M/C REJ WT CR REJ % Cost
21.41 1054 5654.71 3.85 2937 15757.01 10.73 446.9
5.63 689 4145.71 5.74 246 1480.18 2.05 386
5.40 5 127.37 19.23 207 5272.91 796.15 2366.4
3.72 77 1453.76 9.20 120 2265.60 14.34 1347.4
3.40 152 1631.87 5.34 165 1771.44 5.79 1009
3.21 105 2305.80 4.71 41 900.36 1.84 1814.4
3.04 76 1361.01 1.83 94 1683.35 2.26 1236.7
2.93 39 823.10 1.76 100 2110.50 4.52 1755.1
2.61 215 1487.80 6.06 162 1121.04 4.57 471.4
2.37 51 642.80 3.86 137 1726.75 10.37 1229.9
53.72

Top 10 Production Parts by Rejection % wise Top 10 Pro

25.00 20.00
20.00 16.00
15.00 12.00
10.00 8.00
5.00 REJN % 4.00
0.00 0.00
TOTAL REJN WT.
3D
U DY IER 02 90 AN VE
R 14 Y W U DY RIE
R
O R 3 6 8 P O 7 OD NE 3D
B
CA
R SE IL C L E B ) BO AR E
CR 5 CA AC
O O
IP
L
IN
D 22 (8
3
CR C CAS
NG 8 7 TG T D SP CR LH NG 87
5
TG
G
USIN
E HO
SID
 Total Cost
17.84
3.61
5.02
2.65
3.20
2.65
2.10
2.44
1.78
2.31
43.59

Top 10 Production Parts by Rejection Cost wise

20.00
16.00
12.00
8.00
4.00 Total Cost
0.00
U R 2 0 N ER 714
3D DY RIE 30 689 PA O V DY NEW
BO AR E L E BO )
CR C CAS CO OI PL C NDL 22 (83
5 A I I
NG 87 TG T D SP CR LH
NG
I
O US
EH
SID
SR NO. PART WT. PRODN QTY PRODN WT. TOTAL REJN QTY REJN % PART NAME
1 42.07 306 12873.42 173 56.54 SPINDLE 705 (CTL)
2 14.524 1784 25910.82 246 13.79 taco v3 8390
3 18.667 448 8362.82 150 33.48 knuckle 2673
4 18.637 384 7156.61 124 32.29 STEERING HUB 2667
5 16.612 611 10149.93 131 21.44 HOUSING 1001
6 20.74 147 3048.78 99 67.35 HOUSING 2001
7 6.49 1369 8884.81 290 21.18 510 CARRIER
8 3.5 774 2709.00 456 58.91 CHAINA CARRIER
9 5.65 1639 9260.35 238 14.52 PADAMINI 147200100
10 10.017 84 841.43 129 153.57 PLAIN DIFF CASE 9818

TOTAL REJN WT.

8.00 7.28
7.00
6.00
5.00
4.00 3.57
3.00 2.80 TOTAL REJN WT.
2.31 2.18 2.05 1.88 1.60
2.00 1.34 1.29
1.00
0.00
)
TL 90 73 67 01 01 RI
ER
RI
ER 00 81
8
(C 83 26 26 10 20 R R 0 01 9
05 v3 kle
B G G CA CA 2 AS
E
7 co HU SIN SIN 0 A 47
LE ta uc G U U 51 N 1 C
IN
D kn
RIN HO HO AI IN
I
DI
FF
SP EE CH M N
ST DA AI
PA PL
 TOTAL REJN WT. FDY REJ QTY FDY REJ WT FR REJ % M/C REJ QTY M/C REJ WT CR REJ %
7.28 94 3954.58 30.72 79 3323.53 25.82
3.57 83 1205.49 4.65 163 2367.41 9.14
2.80 20 373.34 4.46 130 2426.71 29.02
2.31 27 503.20 7.03 97 1807.79 25.26
2.18 36 598.03 5.89 95 1578.14 15.55
2.05 69 1431.06 46.94 30 622.20 20.41
1.88 57 369.93 4.16 233 1512.17 17.02
1.60 46 161.00 5.94 410 1435.00 52.97
1.34 98 553.70 5.98 140 791.00 8.54
1.29 31 310.53 36.90 98 981.67 116.67

Top 10 Development Parts by Rejection % wise

180.00
160.00 153.57
140.00
120.00
100.00
80.00 56.54
67.35 58.91
60.00
40.00 33.48 32.29 REJN %
13.79 21.44 21.18 14.52
20.00
TOTAL REJN WT. 0.00
) 0
TL 90 73 67 01 01 RI
ER
RI
ER 10 81
8
(C 83 26 26 10 20 R R 0 0 9
05 v3 le B G G CA CA 72 AS
E
7 co ck HU SIN SIN 0 A 4 C
LE ta u NG U U 1 N I1
IN
D kn RI HO HO
5 AI IN DI
FF
SP EE CH M N
ST DA AI
PA PL
REJN %
3DU
Month % Rej
Dec-20 18.30
Jan-21 35.90
% Rej
Feb-21 21.30 30.00
Mar-21 15.40 24.50
25.00 23.80
Apr-21 11.90 22.54
May-21 16.70 20.00
Jun-21 23.80 16.70 16.46
14.58 %R
Jul-21 24.50 15.00
11.90
Aug-21 22.54
10.00
Sep-21 16.46
Oct-21 14.58 5.00

0.00
Apr/21 May/21 Jun/21 Jul/21 Aug/21 Sep/21 Oct/21

Sr No Defects Defectives %Rej Cum %

14 SLAG 1064 26.66 26.66 1200
16 BH 1004 25.16 51.82
19 CORE INCLUSION 742 18.59 70.41
1000
13 SHRINKAGE 209 5.24 75.65
7
10 PIN HOLE 147 3.68 79.33
24 FETT, DAMAGE 147 3.68 83.01 800
18 LOW BHN 120 3.01 86.02 51.82
5 SAND INCLUSION 87 2.18 88.20 600
23 EXCESS FETTLING 78 1.95 90.15
22 CUT SECTION 76 1.90 92.06
400 26.66
7 EXTRA METAL 63 1.58 93.64
4 MOLD CRACK 61 1.53 95.16
3 CASTING SHIFT 50 1.25 96.42 200
26.66 25.16
2 CORE SHIFT 42 1.05 97.47 1
1 SAND DROP 39 0.98 98.45 0
12 SHORT POUR 23 0.58 99.02
6 BOX LEEK 20 0.50 99.52
8 SCABBING 11 0.28 99.80
Defective
Defect
15 COLD 4 0.10 99.90 qty

Slag, Core 1064+742

Inclusion = 1806

17 HIGH BHN 4 0.10 100.00

BH 1004
9 FUSED SAND 0 0.00 100.00
Shrinkage 209
11 K/O DAMAGE 0 0.00 100.00
20 CORE SHIFT 0 0.00 100.00
21 LESS WALL/rusty 0 0.00 100.00
3991
16.46 % Rej
14.58

ep/21 Oct/21

200 100.00
90.15 92.06
86.02 88.20
83.01 90.00
000 79.33
75.65 80.00
70.41
70.00
800
60.00
51.82
600 50.00 Defectives
%Rej
40.00
Cum %
400 26.66 30.00

20.00
200
26.66 25.16
18.59 10.00
5.24 3.68 3.68 3.01 2.18 1.95 1.90
0 0.00

Defect
Root cause analysis Action Taken Effectiveness
contribution

1)Ladle changing frequency Trial Data-

validated for 25 treatments. No.Of Heats-10
1) Ladle changing Pouring qty-1200
26.66+18.59= 2)Core hardness increased (70-
frequency was 35 Defectives- 61
45.25% 80)
treatment. (Foundry+M/C)
3)Laddle design changed from
23th oct. Rejecion %- 5.08 2)Laddle
design–slag effectiveness 1.29
%
Due to low pouring Pouring Temp increased by
25.16%
temp. 10˚C
Rejection contri in Sept,21 was
5.24% - - 8.56%
 From July PPT

100.00

90.00

80.00

70.00

60.00

50.00 Defectives
%Rej
40.00
Cum %
30.00

20.00

10.00

0.00

Current Rejection % targeted

rejection % in month Nov 2021

14.58%
10.00%
Target
Decided10%
NGCR
Month % Rej
Dec-20 % Rej
Jan-21
Feb-21 140.00
116.67
Mar-21 120.00
Apr-21 8.50
100.00
May-21
Jun-21 116.67 80.00 % Rej
Jul-21 4.33 60.00
Aug-21 7.82
Sep-21 4.75 40.00
Oct-21 7.79 20.00 8.50 7.82 7.79
4.33 4.75
0.00
Apr/21 May/21 Jun/21 Jul/21 Aug/21 Sep/21 Oct/21

Sr No Defects Defectives %Rej Cum %

24 FETT, DAMAGE 247 26.42 26.42
23 EXCESS FETTLING 121 12.94 39.36 300
12 SHORT POUR 116 12.41 51.76
5 SAND INCLUSION 92 9.84 61.60
250
9 FUSED SAND 63 6.74 68.34
16 BH 62 6.63 74.97
1 SAND DROP 60 6.42 81.39 200
15 COLD 49 5.24 86.63 51.76
14 SLAG 44 4.71 91.34 150
18 LOW BHN 35 3.74 95.08 39.36
4 MOLD CRACK 17 1.82 96.90
100 26.42
6 BOX LEEK 8 0.86 97.75
7 EXTRA METAL 7 0.75 98.50
11 K/O DAMAGE 7 0.75 99.25 50
26.42
19 CORE INCLUSION 6 0.64 99.89 12.94 12.41
13 SHRINKAGE 1 0.11 100.00 0
2 CORE SHIFT 0 0.00 100.00
3 CASTING SHIFT 0 0.00 100.00
8 SCABBING 0 0.00 100.00
Defective
Defect
10 PIN HOLE 0 0.00 100.00 qty

Fett
247+121=
Damage +
368
Excess Fett

17 HIGH BHN 0 0.00 100.00

 Short Pour 116
20 CORE SHIFT 0 0.00 100.00
21 LESS WALL/rusty 0 0.00 100.00
22 CUT SECTION 0 0.00 100.00
935
 % Rej

75 7.79

p/21 Oct/21

0 95.08 100.00
91.34
86.63 90.00
81.39
0
74.97 80.00
68.34
70.00
0 61.60
60.00
51.76
0 50.00 Defectives
39.36 %Rej
40.00
Cum %
0 26.42 30.00

20.00
0
26.42
10.00
12.94 12.41 9.84 6.74 6.63 6.42 5.24 4.71 3.74
0 0.00

Defect Current
Root cause analysis Action Taken Effectiveness
contribution rejection %

1)Casting handling awareness

26.42+12.94= 1)Improper handling given to workers
39.36% 2)Negligence 2)Amount debited from the 7.79%
To be traced in the month of
respective contractor’s account November Newly occurred
in top 10
 7.79%
To be traced in the month of
Newly occurred
November
in top 10

12.41% Low pouring temp. Pouring temp to be increased

Defectives
%Rej
Cum %

Rejection % targeted
in month Nov 2021

5%
5%
875 Carrier
Month % Rej
Dec-20 % Rej
Jan-21
Feb-21 900.00 815.3
Mar-21 800.00
Apr-21 18.20 700.00
May-21 10.50 600.00
Jun-21 233.00 500.00
Jul-21 13.15 400.00
Aug-21 9.11 300.00 233.00
Sep-21 36.00 200.00
Oct-21 815.38
100.00 18.20 10.50 13.15 9.11 36.00
0.00
Apr/21 May/21 Jun/21 Jul/21 Aug/21 Sep/21 Oct/2

Sr No Defects Defectives %Rej Cum %

13 SHRINKAGE 193 91.04 91.04 250
16 BH 10 4.72 95.75
18 LOW BHN 5 2.36 98.11 98.11
95.75
14 SLAG 2 0.94 99.06 200 91.04
22 CUT SECTION 2 0.94 100.00
1 SAND DROP 0 0.00 100.00
2 CORE SHIFT 0 0.00 100.00 150
3 CASTING SHIFT 0 0.00 100.00
4 MOLD CRACK 0 0.00 100.00
5 SAND INCLUSION 0 0.00 100.00 100 91.04
6 BOX LEEK 0 0.00 100.00
7 EXTRA METAL 0 0.00 100.00
50
8 SCABBING 0 0.00 100.00
9 FUSED SAND 0 0.00 100.00
10 PIN HOLE 0 0.00 100.00 0 4.72 2.36
11 K/O DAMAGE 0 0.00 100.00 SHRINK BH LOW BHN
12 SHORT POUR 0 0.00 100.00 AGE
15 COLD 0 0.00 100.00
Defective
Defect
17 HIGH BHN 0 0.00 100.00 qty

Shrinkage 193
19 CORE INCLUSION 0 0.00 100.00

BH 10
20 CORE SHIFT 0 0.00 100.00
21 LESS WALL/rusty 0 0.00 100.00
23 EXCESS FETTLING 0 0.00 100.00
24 FETT, DAMAGE 0 0.00 100.00
212
% Rej
815.38

% Rej

15 9.11 36.00

21 Aug/21 Sep/21 Oct/21

0 120.00

98.11 99.06 100.00 100.00 100.00 100.00 100.00 100.00

95.75 100.00
0 91.04

80.00
0

60.00 Defectives
%Rej
0 91.04 Cum %
40.00

0
20.00

0 4.72 2.36 0.94 0.94 0.00 0.00 0.00 0.00 0.00 0.00
SHRINK BH LOW BHN SLAG CUT SAND
AGE SECTION DROP

Defect Current
Root cause analysis Action Taken Effectiveness
contribution rejection %
Hot spot generates in Trial to be planned on 27-10-
91.04 Gatting system changed 815.38%
groove area. 2021

Addition vents provided in core Rejection contribution was Target Decided

4.72% Gas entrapment 19.44% in the month of
box 12%
September,21
Defectives
%Rej
Cum %

Rejection % targeted
in month Nov 2021

12%
TG CASE 302
Month % Rej
Dec-20 % Rej
Jan-21
Feb-21 30.00
26.40
Mar-21 24.86
25.00 23.32 23.
Apr-21 26.40
May-21 18.20 20.00 18.20 17.25
Jun-21 12.71
15.00 12.71
Jul-21 23.32
Aug-21 24.86 10.00
Sep-21 17.25
Oct-21 23.54 5.00

0.00
Apr/21 May/21 Jun/21 Jul/21 Aug/21 Sep/21 Oct

Sr No Defects Defectives %Rej Cum %

16 BH 75 38.07 38.07
13 SHRINKAGE 24 12.18 50.25
19 CORE INCLUSION 24 12.18 62.44 80
2 CORE SHIFT 21 10.66 73.10
24 FETT, DAMAGE 16 8.12 81.22 70
1 SAND DROP 12 6.09 87.31
23 EXCESS FETTLING 7 3.55 90.86 60

3 CASTING SHIFT 4 2.03 92.89

50
6 BOX LEEK 3 1.52 94.42
4 MOLD CRACK 2 1.02 95.43 40
50.25
11 K/O DAMAGE 2 1.02 96.45
14 SLAG 2 1.02 97.46 30 38.07
15 COLD 2 1.02 98.48
20
21 LESS WALL/rusty 2 1.02 99.49
22 CUT SECTION 1 0.51 100.00 38.07
10
5 SAND INCLUSION 0 0.00 100.00
12.18
7 EXTRA METAL 0 0.00 100.00 0
8 SCABBING 0 0.00 100.00
9 FUSED SAND 0 0.00 100.00
10 PIN HOLE 0 0.00 100.00
Defective
Defect
12 SHORT POUR 0 0.00 100.00 qty

Blow Hole 75
17 HIGH BHN 0 0.00 100.00
18 LOW BHN 0 0.00 100.00
20 CORE SHIFT 0 0.00 100.00
197
% Rej

24.86
2 23.54

17.25
% Rej

1 Aug/21 Sep/21 Oct/21

80 120.00

70
92.89 94.42 95.43 100.00
90.86
87.31
60
81.22
73.10 80.00
50
62.44
40 60.00 Defectives
50.25
%Rej
30 38.07 Cum %
40.00
20
38.07 20.00
10
12.18 12.18 10.66 8.12 6.09 3.55 2.03 1.52 1.02
0 0.00

Defect Current
Root cause analysis Action Taken Effectiveness
contribution rejection %
23.54%
To escape the gas, vents are Trial to be taken before 31-10-
35.29% Excess core moisture. Target
provided on cores by drilling 2021
Decided15%
Defectives
%Rej
Cum %

Rejection % targeted
in month Nov 2021

15.00%
TACO 6890
Month % Rej
Dec-20 % Rej
Jan-21
Feb-21 30.00
Mar-21 24.23
25.00
Apr-21
May-21 20.00
16.30
Jun-21 16.30
15.00 13.37
Jul-21 10.29 11.13
10.29
Aug-21 13.37 10.00
Sep-21 24.23
Oct-21 11.13 5.00

0.00
Apr/21 May/21 Jun/21 Jul/21 Aug/21 Sep/21 Oct/2

Sr No Defects Defectives %Rej Cum %

16 BH 155 48.90 48.90
1 SAND DROP 51 16.09 64.98 180
14 SLAG 21 6.62 71.61
19 CORE INCLUSION 21 6.62 78.23 160
4 MOLD CRACK 19 5.99 84.23 140
6 BOX LEEK 14 4.42 88.64
7
11 K/O DAMAGE 13 4.10 92.74 120 71.61
7 EXTRA METAL 6 1.89 94.64 64.98
100
15 COLD 5 1.58 96.21
24 FETT, DAMAGE 5 1.58 97.79 80 48.90
2 CORE SHIFT 4 1.26 99.05
60
10 PIN HOLE 1 0.32 99.37
12 SHORT POUR 1 0.32 99.68 40 48.90
23 EXCESS FETTLING 1 0.32 100.00
3 CASTING SHIFT 0 0.00 100.00 20
16.09
5 SAND INCLUSION 0 0.00 100.00 6.62
0
8 SCABBING 0 0.00 100.00
9 FUSED SAND 0 0.00 100.00
13 SHRINKAGE 0 0.00 100.00
Defective
Defect
17 HIGH BHN 0 0.00 100.00 qty
 Blow hole 155

18 LOW BHN 0 0.00 100.00

Sand Drop 51

20 CORE SHIFT 0 0.00 100.00

21 LESS WALL/rusty 0 0.00 100.00

22 CUT SECTION 0 0.00 100.00

317
% Rej

24.23

% Rej
13.37
9 11.13

1 Aug/21 Sep/21 Oct/21

120.00

96.21 97.79
92.74 94.64 100.00
88.64
84.23
78.23
71.61 80.00
64.98
60.00 Defectives
48.90 %Rej
Cum %
40.00

48.90
20.00

16.09
6.62 6.62 5.99 4.42 4.10 1.89 1.58 1.58 0.00

Defect Current
Root cause analysis Action Taken Effectiveness
contribution rejection %
 1)Core oven temp maintained
on 170˚C for 90min
2)SG boring avoided in a Rejection contribution was
48.90% Gas Entrapment charge mix (old charge mix 66.40% in the month of
used) September,21
3)Graphite paint used at 11.13%
specific location Target Decided
12%

From 19th Oct, Casting

1)Low compatibility 1)Compatibility increased (44)
produced with trial are756 out
16.09% (40-42) 2)Proper Crush pad to be added
of 8 rejected due to sand drop at
2)Improper Crush pad on pattern
foundry stage
Defectives
%Rej
Cum %

Rejection % targeted
in month Nov 2021
8%
Oil Pan
Month % Rej
Dec-20 % Rej
Jan-21
7.00 6.54
Feb-21
5.85
Mar-21 6.00 5.60 5.50
Apr-21 4.90 4.90
5.00
May-21 5.60
Jun-21 5.50 4.00 3.54
3.27
Jul-21 3.54 3.00
Aug-21 5.85
Sep-21 3.27 2.00
Oct-21 6.54 1.00

0.00
Apr/21 May/21 Jun/21 Jul/21 Aug/21 Sep/21 Oct/21

Sr No Defects Defectives %Rej Cum %

11 K/O DAMAGE 33 22.60 22.60 35
12 SHORT POUR 27 18.49 41.10
16 BH 25 17.12 58.22 30
4 MOLD CRACK 15 10.27 68.49
1 SAND DROP 10 6.85 75.34 25
8 SCABBING 7 4.79 80.14
58.22
15 COLD 6 4.11 84.25 20
23 EXCESS FETTLING 5 3.42 87.67
6 BOX LEEK 4 2.74 90.41 41.10
15
24 FETT, DAMAGE 4 2.74 93.15
3 CASTING SHIFT 3 2.05 95.21 10 22.60
14 SLAG 3 2.05 97.26
7 EXTRA METAL 2 1.37 98.63 5
22.60
9 FUSED SAND 2 1.37 100.00 18.49 17.12
2 CORE SHIFT 0 0.00 100.00 0
5 SAND INCLUSION 0 0.00 100.00
10 PIN HOLE 0 0.00 100.00
13 SHRINKAGE 0 0.00 100.00
Defective Defect
Defect
17 HIGH BHN 0 0.00 100.00 qty contribution

K/O
33 22.60%
Damage
18 LOW BHN 0 0.00 100.00

Shourt
27 18.49%
pour
19 CORE INCLUSION 0 0.00 100.00
20 CORE SHIFT 0 0.00 100.00
21 LESS WALL/rusty 0 0.00 100.00
22 CUT SECTION 0 0.00 100.00
146
 6.54

% Rej
3.27

Sep/21 Oct/21

93.15 100.00
90.41
87.67
84.25 90.00
80.14
75.34 80.00
68.49
70.00
58.22
60.00

50.00 Defectives
41.10
%Rej
40.00
Cum %
30.00
.60
20.00
.60 18.49 10.00
17.12
10.27 6.85 4.79 4.11 3.42 2.74 2.74 0.00

Current
Root cause analysis Action Taken Effectiveness
rejection %
Because of less
Need to strengthen the pads by Date to be decided with
thickness resting pad
modifying shape development team
becoming weak
6.54%
Target
C/S area of down sprue Decided3%
100% visual inspection of down
getting reduced due to To be observed in November
sprue
sand fall
Defectives
%Rej
Cum %

Rejection % targeted
in month Nov 2021

3%
DIPL cover
Month % Rej
Dec-20 % Rej
Jan-21
10.00 9.36
Feb-21
9.00
Mar-21
8.00
Apr-21 1.00
7.00
May-21 2.50
6.00
Jun-21 2.63
5.00 4.09
Jul-21 3.81 3.81
4.00
Aug-21 9.36 2.63 2.67
3.00 2.50
Sep-21 2.67
2.00 1.00
Oct-21 4.09
1.00
0.00
Apr/21 May/21 Jun/21 Jul/21 Aug/21 Sep/21 Oct/21

Sr No Defects Defectives %Rej Cum %

16 BH 44 25.88 25.88
21 Exess S/B 39 22.94 48.82 50
14 SLAG 23 13.53 62.35
45
24 FETT, DAMAGE 20 11.76 74.12
12 SHORT POUR 10 5.88 80.00 40
2 CORE SHIFT 9 5.29 85.29
35
13 SHRINKAGE 8 4.71 90.00
3 CASTING SHIFT 7 4.12 94.12 30
62.
22 CUT SECTION 3 1.76 95.88 25
6 BOX LEEK 2 1.18 97.06 48.82
20 CORE SHIFT 2 1.18 98.24 20
11 K/O DAMAGE 1 0.59 98.82 15
25.88
17 HIGH BHN 1 0.59 99.41
10
23 EXCESS FETTLING 1 0.59 100.00
1 SAND DROP 0 0.00 100.00 5 25.88 22.94
13.
4 MOLD CRACK 0 0.00 100.00 0
5 SAND INCLUSION 0 0.00 100.00 BH Exess S/B SLA
7 EXTRA METAL 0 0.00 100.00
8 SCABBING 0 0.00 100.00
Defective
Defect
9 FUSED SAND 0 0.00 100.00 qty

BH 44
10 PIN HOLE 0 0.00 100.00
 Excess SB 39

15 COLD 0 0.00 100.00

18 LOW BHN 0 0.00 100.00
19 CORE INCLUSION 0 0.00 100.00
170
% Rej
9.36

% Rej
1 4.09

2.67

1 Aug/21 Sep/21 Oct/21

50 120.00

45
95.88 97.06 100.00
94.12
40 90.00
85.29
35 80.00
74.12 80.00
30
62.35
25 60.00 Defectives
48.82 %Rej
20
Cum %
40.00
15
25.88
10
20.00
5 25.88 22.94
13.53 11.76
5.88 5.29 4.71 4.12 1.76 1.18
0 0.00
BH Exess S/B SLAG FETT, SHORT CORE
DAMAGE POUR SHIFT

Defect Current
Root cause analysis Action Taken Effectiveness
contribution rejection %

Temp drop due to Dirty

25.88 Validation of CI pouring ladle
ladle

4.09%
Newly occurred
in top 10
 4.09%
1)Castings not to be shot Newly occurred
blasted until cooled down to in top 10
room temp In process
22.94 Negligence
2)Shot blasting timing & shot
level to be strictly monitored at
starting of each shift
Defectives
%Rej
Cum %

Rejection % targeted
in month Nov 2021

3%
3%
Spindle 714
Month % Rej
Dec-20 % Rej
Jan-21
Feb-21 8.00 7.30 7.19
Mar-21 7.00 6.28
6.00 5.99 6.04
Apr-21 6.00 6.00
May-21 7.30 4.97
5.00
Jun-21 7.19
4.00
Jul-21 5.99
Aug-21 4.97 3.00
Sep-21 6.04 2.00
Oct-21 6.28 1.00
0.00
Apr/21 May/21 Jun/21 Jul/21 Aug/21 Sep/21 Oct/2

Sr No Defects Defectives %Rej Cum %

14 SLAG 42 30.22 30.22
13 SHRINKAGE 27 19.42 49.64 45
1 SAND DROP 22 15.83 65.47
16 BH 21 15.11 80.58 40
2 CORE SHIFT 8 5.76 86.33 35
24 FETT, DAMAGE 8 5.76 92.09
3 CASTING SHIFT 4 2.88 94.96 30
6 BOX LEEK 2 1.44 96.40 6
25
19 CORE INCLUSION 2 1.44 97.84
10 PIN HOLE 1 0.72 98.56 20 49.64
17 HIGH BHN 1 0.72 99.28
15
22 CUT SECTION 1 0.72 100.00 30.22
4 MOLD CRACK 0 0.00 100.00 10
5 SAND INCLUSION 0 0.00 100.00
5 30.22
7 EXTRA METAL 0 0.00 100.00 19.42 1
8 SCABBING 0 0.00 100.00 0
9 FUSED SAND 0 0.00 100.00
11 K/O DAMAGE 0 0.00 100.00
12 SHORT POUR 0 0.00 100.00
Defective
Defect
15 COLD 0 0.00 100.00 qty

Slag +
42+27 =69
Shrinkage
18 LOW BHN 0 0.00 100.00
20 CORE SHIFT 0 0.00 100.00
21 LESS WALL/rusty 0 0.00 100.00
23 EXCESS FETTLING 0 0.00 100.00
139
% Rej

6.04 6.28

4.97
% Rej

1 Aug/21 Sep/21 Oct/21

45 120.00

40 98.56
96.40 97.84
94.96 100.00
92.09
35 86.33
80.58
30 80.00
65.47
25
60.00 Defectives
20 49.64
%Rej
Cum %
15 40.00
30.22
10
20.00
5 30.22
19.42 15.83 15.11
5.76 5.76 2.88 1.44 1.44 0.72
0 0.00

Defect Current
Root cause analysis Action Taken Effectiveness
contribution rejection %
6.28%
30.22+19.42 New Laddle design
Under process Under monitering Target Decided
=49.64% implimented from 23 oct-21
5%
Defectives
%Rej
Cum %

Rejection % targeted
in month Nov 2021

5.00%
CR-22
Month % Rej
Dec-20 6.94 % Rej
Jan-21 8.68
Feb-21 9.70 14.00
11.90
Mar-21 9.60 12.00 11.00
10.20 10.63
Apr-21 11.00 10.00
10.00 9.31
May-21 10.00
7.65
Jun-21 11.90 8.00
Jul-21 10.20 6.00
Aug-21 7.65
Sep-21 9.31 4.00
Oct-21 10.63 2.00

0.00
Apr/21 May/21 Jun/21 Jul/21 Aug/21 Sep/21 Oct/21

Sr No Defects Defectives %Rej Cum %

14 SLAG 78 20.69 20.69 90
24 FETT, DAMAGE 61 16.18 36.87
2 CORE SHIFT 48 12.73 49.60 80
9 FUSED SAND 34 9.02 58.62 70
1 SAND DROP 33 8.75 67.37
16 BH 30 7.96 75.33 60
58
5 SAND INCLUSION 19 5.04 80.37
50 49.60
18 LOW BHN 18 4.77 85.15
23 EXCESS FETTLING 13 3.45 88.59 40
36.87
11 K/O DAMAGE 9 2.39 90.98
30
4 MOLD CRACK 8 2.12 93.10
20.69
7 EXTRA METAL 8 2.12 95.23 20
6 BOX LEEK 6 1.59 96.82
10 20.69
15 COLD 5 1.33 98.14 16.18 12.73 9.
19 CORE INCLUSION 4 1.06 99.20 0
22 CUT SECTION 3 0.80 100.00
3 CASTING SHIFT 0 0.00 100.00
8 SCABBING 0 0.00 100.00
Defective Defect
Defect
10 PIN HOLE 0 0.00 100.00 qty contribution
SLAG/
78 20.69%
12 SHORT POUR 0 0.00 100.00 inclusion
 Fett
61 16.18%
Damage

13 SHRINKAGE 0 0.00 100.00

17 HIGH BHN 0 0.00 100.00
20 CORE SHIFT 0 0.00 100.00
21 LESS WALL/rusty 0 0.00 100.00
377
 10.63
9.31

% Rej

Sep/21 Oct/21

100.00
90.98
88.59
85.15 90.00
80.37
75.33 80.00
67.37 70.00
58.62
60.00
49.60
50.00 Defectives
36.87 %Rej
40.00
Cum %
30.00
.69
20.00

.69 16.18 10.00

12.73 9.02 8.75 7.96 5.04 4.77 3.45 2.39 0.00

Current
Root cause analysis Action Taken Effectiveness
rejection %

Turbulent flow Gating Layout changed.

10.63%
To be monitored in November Target Decided
6%
 10.63%
1)Casting handling awareness To be monitored in November Target Decided
1)Improper handling given to workers 6%
2)Negligence 2)Amount debited from the
respective contractor’s account
 From July PPT

Defectives
%Rej
Cum %

Rejection % targeted
in month Nov 2021

6.00%
6.00%
SIDE HOUSING LH (83) NEW
Month % Rej
Dec-20 % Rej
Jan-21
Feb-21 16.00
14.23
Mar-21 14.00
Apr-21 12.00
May-21 9.79
10.00 8.50
Jun-21 7.05 7.75
8.00 7.05
Jul-21 9.79
Aug-21 7.75 6.00
Sep-21 8.50 4.00
Oct-21 14.23 2.00
0.00
Apr/21 May/21 Jun/21 Jul/21 Aug/21 Sep/21 Oct/21

Sr No Defects Defectives %Rej Cum %

13 SHRINKAGE 67 35.64 35.64
23 EXCESS FETTLING 26 13.83 49.47 80
1 SAND DROP 23 12.23 61.70
15 COLD 19 10.11 71.81 70
24 FETT, DAMAGE 19 10.11 81.91
14 SLAG 16 8.51 90.43 60
16 BH 11 5.85 96.28
50
11 K/O DAMAGE 3 1.60 97.87
61
10 PIN HOLE 2 1.06 98.94 40
5 SAND INCLUSION 1 0.53 99.47 49.47
19 CORE INCLUSION 1 0.53 100.00 30
35.64
2 CORE SHIFT 0 0.00 100.00
3 CASTING SHIFT 0 0.00 100.00 20
4 MOLD CRACK 0 0.00 100.00 35.64
10
6 BOX LEEK 0 0.00 100.00
13.83 12
7 EXTRA METAL 0 0.00 100.00 0
8 SCABBING 0 0.00 100.00 SHRINK EXCESS SA
9 FUSED SAND 0 0.00 100.00 AGE FETTLING DR
12 SHORT POUR 0 0.00 100.00
Defective
Defect
17 HIGH BHN 0 0.00 100.00 qty

Shrinkage 67
18 LOW BHN 0 0.00 100.00

Excess Fett 26
20 CORE SHIFT 0 0.00 100.00

Sand Drop 23
21 LESS WALL/rusty 0 0.00 100.00
22 CUT SECTION 0 0.00 100.00
188
% Rej
14.23

9
8.50 % Rej
7.75

1 Aug/21 Sep/21 Oct/21

80 120.00

70 97.87 98.94 99.47

96.28 100.00
90.43
60 81.91
71.81 80.00
50
61.70
40 60.00 Defectives
49.47
%Rej
30 Cum %
35.64 40.00
20

35.64 20.00
10
13.83 12.23 10.11 10.11 8.51 5.85 1.60 1.06 0.53
0 0.00
SHRINK EXCESS SAND COLD FETT, SLAG
AGE FETTLING DROP DAMAGE

Defect
Root cause analysis Action Taken Effectiveness
contribution

35.64% Cold riser Cold riser to be made hot.

Contractor negligence Training to be provided.

13.83% Monitor in nov. first week

Dry sand Compactibility to be kept on

12.23% higher side. (42)
 120.00

99.47
100.00

80.00

60.00 Defectives
%Rej
Cum %
40.00

20.00

0.53 0.00

Current Rejection % targeted

rejection % in month Nov 2021

14.23%
Newly occurred 9.00%
in top 10
 Month No. Of Complaints
April 8
May 8
June 12
July 12
August 14
September 4
October 4

Customer Complaints
16
14
14
12 12
12
10
8 8
8 No. Of Complaints
6
4 4
4
2
0
ril ay ne Ju
ly us
t
be
r
be
r
Ap M Ju g m to
Au pt
e O c
Se
 Defective Defect
Part Name Defect Root cause analysis
qty contribution

1) Ladle changing
Slag, Core 1064+742= 26.66+18.59=
frequency was 35
Inclusion 1806 45.25%
treatment.
3DU

Due to low pouring

BH 1004 25.16%
temp.

Shrinkage 209 5.24% -

Fett
247+121= 26.42+12.94= 1)Improper handling
Damage +
368 39.36% 2)Negligence
NGCR Excess Fett

Short Pour 116 12.41% Low pouring temp.

Hot spot generates in

Shrinkage 193 91.04
groove area.
875 Carrier
BH 10 4.72% Gas entrapment

TG Case 302 Blow Hole 75 35.29% Excess core moisture.

Blow hole 155 48.90% Gas Entrapment

Taco 6890

1)Low compatibility
Sand Drop 51 16.09% (40-42)
2)Improper Crush pad

Because of less
K/O
33 22.60% thickness resting pad
Damage
becoming weak
Oil Pan
 Oil Pan
C/S area of down sprue
Shourt pour 27 18.49% getting reduced due to
sand fall

Temp drop due to Dirty

BH 44 25.88
ladle

Dipl Cover
Excess SB 39 22.94 Negligence

Slag + 30.22+19.42
Spindle 714 Shrinkage
42+27 =69
=49.64%
Under process

SLAG/
78 20.69% Turbulent flow
inclusion

CR 22 Body
Fett 1)Improper handling
61 16.18%
Damage 2)Negligence

Shrinkage 67 35.64% Cold riser

Contractor negligence
Side hsg LH(83) New Excess Fett 26 13.83%

Dry sand
Sand Drop 23 12.23%
 Current Rejection % targeted
Action Taken Effectiveness in month Nov 2021
rejection %

1)Ladle changing frequency Trial Data-

validated for 25 treatments. No.Of Heats-10
2)Core hardness increased (70- Pouring qty-1200
80) Defectives- 61
(Foundry+M/C) 14.58%
3)Laddle design changed from
23th oct. Rejecion %- 5.08 2)Laddle 10.00%
design–slag effectiveness 1.29 Target
% Decided10%
Pouring Temp increased by
10˚C

- Rejection contri in Sept,21 was

8.56%

1)Casting handling awareness

given to workers
2)Amount debited from the 7.79%
To be traced in the month of
respective contractor’s account November Newly occurred 5%
in top 10

Pouring temp to be increased

Gatting system changed Trial to be planned on 27-10- 815.38%

2021
12%
Addition vents provided in core Rejection contribution was Target Decided
box 19.44% in the month of 12%
September,21
23.54%
To escape the gas, vents are Trial to be taken before 31-10-
Target 15.00%
provided on cores by drilling 2021
Decided15%

1)Core oven temp maintained

on 170˚C for 90min
2)SG boring avoided in a Rejection contribution was
charge mix (old charge mix 66.40% in the month of
used) September,21
3)Graphite paint used at 11.13%
specific location Target Decided 8%
12%

From 19th Oct, Casting

1)Compatibility increased (44)
produced with trial are756 out
2)Proper Crush pad to be added
of 8 rejected due to sand drop at
on pattern
foundry stage

Need to strengthen the pads by Date to be decided with

modifying shape development team
6.54%
Target 3%
Decided3%
 6.54%
Target 3%
Decided3%
100% visual inspection of down
To be observed in November
sprue

Validation of CI pouring ladle

1)Castings not to be shot 4.09%

blasted until cooled down to Newly occurred 3%
room temp In process in top 10
2)Shot blasting timing & shot
level to be strictly monitored at
starting of each shift

6.28%
New Laddle design
Under monitering Target Decided 5.00%
implimented from 23 oct-21
5%

Gating Layout changed.

10.63%
1)Casting handling awareness To be monitored in November Target Decided 6.00%
given to workers 6%
2)Amount debited from the
respective contractor’s account

Cold riser to be made hot.

Training to be provided. 14.23%

Monitor in nov. first week Newly occurred 9.00%
in top 10
Compactibility to be kept on
higher side. (44)
 Defective Defect
Part Name Defect Root cause analysis
qty contribution

1) Ladle changing
Slag, Core 1064+742= 26.66+18.59=
frequency was 35
Inclusion 1806 45.25%
treatment.
3DU

Due to low pouring

BH 1004 25.16%
temp.

Shrinkage 209 5.24% -

Fett
247+121= 26.42+12.94= 1)Improper handling
Damage +
368 39.36% 2)Negligence
NGCR Excess Fett

Short Pour 116 12.41% Low pouring temp.

Hot spot generates in

Shrinkage 193 91.04
groove area.
875 Carrier
BH 10 4.72% Gas entrapment

TG Case 302 Blow Hole 75 35.29% Excess core moisture.

Blow hole 155 48.90% Gas Entrapment

Taco 6890

1)Low compatibility
Sand Drop 51 16.09% (40-42)
2)Improper Crush pad

Because of less
K/O
33 22.60% thickness resting pad
Damage
becoming weak
Oil Pan
 Oil Pan
C/S area of down sprue
Shourt pour 27 18.49% getting reduced due to
sand fall

Temp drop due to Dirty

BH 44 25.88
ladle

Dipl Cover
Excess SB 39 22.94 Negligence

Slag + 30.22+19.42
Spindle 714 Shrinkage
42+27 =69
=49.64%
Under process

SLAG/
78 20.69% Turbulent flow
inclusion

CR 22 Body
Fett 1)Improper handling
61 16.18%
Damage 2)Negligence

Shrinkage 67 35.64% Cold riser

Contractor negligence
Side hsg LH(83) New Excess Fett 26 13.83%

Dry sand
Sand Drop 23 12.23%
 Current Rejection % targeted
Action Taken Effectiveness in month Nov 2021
rejection %

1)Ladle changing frequency Trial Data-

validated for 25 treatments. No.Of Heats-10
2)Core hardness increased (70- Pouring qty-1200
80) Defectives- 61
(Foundry+M/C) 14.58%
3)Laddle design changed from
23th oct. Rejecion %- 5.08 2)Laddle 10.00%
design–slag effectiveness 1.29 Target
% Decided10%
Pouring Temp increased by
10˚C

- Rejection contri in Sept,21 was

8.56%

1)Casting handling awareness

given to workers
2)Amount debited from the 7.79%
To be traced in the month of
respective contractor’s account November Newly occurred 5%
in top 10

Pouring temp to be increased

Gatting system changed Trial to be planned on 27-10- 815.38%

2021
12%
Addition vents provided in core Rejection contribution was Target Decided
box 19.44% in the month of 12%
September,21
23.54%
To escape the gas, vents are Trial to be taken before 31-10-
Target 15.00%
provided on cores by drilling 2021
Decided15%

1)Core oven temp maintained

on 170˚C for 90min
2)SG boring avoided in a Rejection contribution was
charge mix (old charge mix 66.40% in the month of
used) September,21
3)Graphite paint used at 11.13%
specific location Target Decided 8%
12%

From 19th Oct, Casting

1)Compatibility increased (44)
produced with trial are756 out
2)Proper Crush pad to be added
of 8 rejected due to sand drop at
on pattern
foundry stage

Need to strengthen the pads by Date to be decided with

modifying shape development team
6.54%
Target 3%
Decided3%
 6.54%
Target 3%
Decided3%
100% visual inspection of down
To be observed in November
sprue

Validation of CI pouring ladle

1)Castings not to be shot 4.09%

blasted until cooled down to Newly occurred 3%
room temp In process in top 10
2)Shot blasting timing & shot
level to be strictly monitored at
starting of each shift

6.28%
New Laddle design
Under monitering Target Decided 5.00%
implimented from 23 oct-21
5%

Gating Layout changed.

10.63%
1)Casting handling awareness To be monitored in November Target Decided 6.00%
given to workers 6%
2)Amount debited from the
respective contractor’s account

Cold riser to be made hot.

Training to be provided. 14.23%

Monitor in nov. first week Newly occurred 9.00%
in top 10
Compactibility to be kept on
higher side. (44)
 Fettling Rejection
Month Working Days
(Tonne)
Sep-21 26 10.796
Oct-21 26 13.590
Nov-21 19 5.966