Regional TPIA Inspectors (5) Inspection Status

Period : May’21 to January’22

Engine Division
Quality improvement points by using TPIA at regions.
 Quality Improvement Points & Implementation Status
Monitoring Sheet
No of Inspectors : 5 May to Oct 2021

Batch Quantity
SL No, of inspection visit Type of component Batch Quantity Batch Quantity rejected at
Region
NO suppliers (Batch) accepted at supplier rejected at supplier receiving area
TPI

1
Pune 102 159 158 1Batch (91Qty) 4

2
Bangalore 183 225 208 17 8

3
Mysore 60 74 72 1 10

4 Kolhapur 101 203 199 4 1

5 Coimbatore 43 82 81 1 1

Pl up date up to end of Oct’21

 Quality Improvement Points & Implementation Status
Monitoring Sheet

No of Inspectors at regions : 5 May to Oct’21

No. of pressure No. of Interference

No. of No. of Quality Introduction of testing fixtures fixtures
No. of Quality No. of
Types of No. of plans available CPK=1.33min
SL plans special
Region compo- critical parts for critical parts for machined
NO prepared by gauges
nets inspected at suppliers sent critical
TPIA introduced.
inspected by Division dimensions AV NA NI AV NA NI

1
Pune 67 12 3 8 7 1 8 - - NA NA NA

2
Bangalore 127 42 12 10 15 NIL 6 - - 1 - -

3
Mysore 52 22 - - NIL NIL - - - - - -

4
Kolhapur 63 28 5 11 NIL NIL 4 - - NA NA NA

5
Coimbator 61 18 - 3 1 NIL - - NA NA NA
e

AV-Available. NA-Not Available. NI-Newly Introduced

 Quality Improvement Points & Implementation Status
Monitoring Sheet

No of Inspectors at regions : 4 November’21

No. of pressure No. of Interference

No. of No. of Quality Introduction of testing fixtures fixtures
No. of Quality No. of
Types of No. of plans available CPK=1.33min
SL plans special
Region compo- critical parts for critical parts for machined
NO prepared by gauges
nets inspected at suppliers sent critical
TPIA introduced.
inspected by Division dimensions AV NA NI AV NA NI

1
Pune 22 16 3 NIL 3 NIL - - - NA NA NA

2
Bangalore 45 12 8 5 9 NA 1 - - 3 - -

3
Belgaum 24 7 1 1 NIL NIL 2 - - NA NA NA

4
Kolhapur 8 2 NIL NIL NIL NIL - - - NA NA NA

AV-Available. NA-Not Available. NI-Newly Introduced

 Quality Improvement Points & Implementation Status
Monitoring Sheet

No of Inspectors at regions : 5 December 21

No. of pressure No. of Interference

No. of No. of Quality Introduction of testing fixtures fixtures
No. of Quality No. of
Types of No. of plans available CPK=1.33min
SL plans special
Region compo- critical parts for critical parts for machined
NO prepared by gauges
nets inspected at suppliers sent critical
TPIA introduced.
inspected by Division dimensions AV NA NI AV NA NI

1
Pune 26 19 3 8 NIL 1 - - - - - 2

2
Bangalore 84 18 All AV 1 16 1 In Progress - - - - - 6

3
Belgaum 28 10 NA NIL NIL NIL - - - NA NA NA

4
Kolhapur 39 13 AV NIL NA In Progress NA - - NA NA NA

5 Mysore 92 18 ALL AV NIL NA NIL 1 - - 1 - -

AV-Available. NA-Not Available. NI-Newly Introduced

 Quality Improvement Points & Implementation Status
Monitoring Sheet

No of Inspectors at regions : 5 January 22

No. of pressure No. of Interference

No. of No. of Quality Introduction of testing fixtures fixtures
No. of Quality No. of
Types of No. of plans available CPK=1.33min
SL plans special
Region compo- critical parts for critical parts for machined
NO prepared by gauges
nets inspected at suppliers sent critical
TPIA introduced.
inspected by Division dimensions AV NA NI AV NA NI

1
Pune 28 20 3 8 NIL 1 - - - - - 2

2
Bangalore 85 19 All AV 1 16 1 - - - - - 6

3
Belgaum 24 10 2 NIL NIL NIL - - - NA NA NA

4
Kolhapur 29 22 All AV NIL NA 2 NA - - NA NA NA

5 Mysore 80 18 ALL AV NIL NA NIL 1 - - 1 - -

AV-Available. NA-Not Available. NI-Newly Introduced

In-house TPIA Inspectors (2+3) Inspection Status

Period : May’21 to Jan 22

Engine Division
 STATUS OF TPIA INSPECTION – INHOUSE – MYSORE
Receiving Inspection May’21-jan’22

No. of quality plans for critical

parts.
No. of Significant action to avoid rejections/
Area of
Sl no Working Inspector batches Acc Rej Parc-Rej Revised /
quality improvement during
inspected Not-Avail new To be Assembly and testing
Avail
Prepared Prepared

1. Repetitive interaction with

1 vendor for quality
Anil Kumar.H 278 1 1 142 60 improvement.
280
2. Technical points shared to
Regional TPI’S with the
requirement of Quality
Aspects regarding to below
parts.
a) Ventilator shaft
b) Fan Drive
Receiving For CQA Parts c) Oil Supply and return Tube
insp. d) Intake manifold leakage
improvement.
Vendor’s report follow up.
1. Engaging all the CQA
2 inspection Activities.
Pundalik 365 362 2 1 145 65 2. Daily Inbound list follow up
and clearing the parts in sap
within Time.
3. Controlled the bypass of the
third party inspection as
much as possible.
 STATUS OF TPIA INSPECTION – INHOUSE - MYSORE
In-house inspection Machine shop May’21-Nov’21

No of
Sl. Location Inspector components Observations Feed backs Resolved Significant improvements / Assignments
No inspected

1. Quick checking fixture list prepared for all line to

reduce CMM run time.
2. List prepared of special gauges request given in
machine shop & Reviewed status of available
gauges.
3. Critical bore dimensions list prepared and
availability of gauges of all line.
4. WIP components laying in shop floor list
prepared for traceability of components.
5. Missing numbers of components of all line
monthly status.
6. Stage wise and product audit 100 % of
component checking increased to reduce
Machine
1 Rahul k 150 - 6 4 deviations repeatedly.
Shop
7. Increased in frequency of checking of component
100 % with available gauges.
8. Check sheet prepared for product audit for all
series cylinder block and cylinder head.
9. DPT conducted on machine shop components to
check for surface cracks.
10. Dimensional check sheet prepared for machine
shop FCT components before and after 100 hrs.
and PPT prepared for FCT components for CQA.
11. List prepared for status of casting quality in
machine shop components.
12. Dynamic check sheet with 26 points is ensured
before final clearance of Tatra crankcase
 STATUS OF TPIA INSPECTION – INHOUSE - MYSORE
In-house inspection Machine shop Dec’-2021

No of
Sl. Significant improvements / Assignments
No Location Inspector components Observations Feed backs Resolved
inspected

1. List of master components references prepared

for machine shop.
2. 140 con rod master done for side mill & bolt seat
fixture.
3. Defective U plug segregation done and check
sheet written for all diameters from bay-2/bay-
4/stores/bin.
4. Quick checking fixture for con rod small end key
stone milling and tatra key way milling gauge IOM
given.
5. DPT done on 170 cylinder block on liner bore for
surface hole and found ok.
1 Machine Rahul k 60 - 2 2 6. During stage audit in VSGM for 140 cylinder head
Shop valve guide reaming not done in exhaust port
feedback given for the same , cross checked with
same batch qty found ok.
7. During stage audit on bay-1 GFM check sheet not
recorded by operator feedback given to correct
the same.
8. Dia 30 U plug defective cross checked from
assembly/testing/truck division for all series and
replaced with vendor name M/S slee .
9. 105 6D Cylinder block crack on oil pan surface
DPT done .
 STATUS OF TPIA INSPECTION – INHOUSE - MYSORE
In-house inspection Machine shop JAN’-2022

No of
Sl. Significant improvements / Assignments
No Location Inspector components Observations Feed backs Resolved
inspected

1. List of master components references prepared

for machine shop.
2. 140 con rod master done for side mill & bolt seat
fixture.
3. Defective U plug segregation done and check
sheet written for all diameters from bay-2/bay-
4/stores/bin.
4. Quick checking fixture for con rod small end key
stone milling and tatra key way milling gauge IOM
given.
5. DPT done on 170 cylinder block on liner bore for
surface hole and found ok.
1 Machine Rahul k 45 - 1 1 6. During stage audit in VSGM for 140 cylinder head
Shop valve guide reaming not done in exhaust port
feedback given for the same , cross checked with
same batch qty found ok.
7. During stage audit on bay-1 GFM check sheet not
recorded by operator feedback given to correct
the same.
8. Dia 30 U plug defective cross checked from
assembly/testing/truck division for all series and
replaced with vendor name M/S slee .
9. 105 6D Cylinder block crack on oil pan surface
DPT done .
 STATUS OF TPIA INSPECTION – INHOUSE - MYSORE
In-house inspection-Testing May’21-Nov’21

No of engines Feed Significant improvements / Assignments

Sl.No Location Inspector Observations Resolved
inspected backs

1. Detail report made for repeated problems

Observed during testing in 170 series engines.
2. Adjusting Screw Less oil flow In rocker arm screw,
probable root cause found and feedback given to
vendor for corrective action.
3. Monitoring of issues observed in HDT Engines
during testing and giving feedbacks to
concerned departments on weekly basis.
4. Monitoring of Customer Complaints from Y
division ,KGF and Palakad for taking corrective
action.
5. Involved in resolving leakage problem in
Auto shut off valve(ETS) during engine testing.
6. Monitoring of HDT Engine intercooler performance
1 Testing Harikrishnan 200 - 5 4
during engine testing and forwarding feedback to
the supplier.
7. Recording, downloading and monitoring of
170 series engine vibration using vibrometer for
further analysis.
8. Inspecting the functioning of ERCH Unit of all
HDT engines and data downloading using software.
9. Display of Alternator Final Assembly guidance Chart.
10. Monitoring of Oil Analysis & coolant analysis
reports and creating Trend Chart for presentation.
11. Temperature Mapping of all HDT engines during
engine testing.
12. Establishment of Compressor testing facility in test
cell in under progress
 Dec-21 TO JAN 2022
STATUS OF TPIA INSPECTION – INHOUSE - MYSORE
In-house Inspection-Testing
No of engines Significant improvements / Assignments
Sl.No Location Inspector Observations Feedbacks Resolved
inspected

1) Display of Muffler, Fan and Air cleaner of

Engine Leak Test-74 different models displayed at dispatch area for
operator guidance-To eliminate the confusion
Engine Final Dispatch of different models during final assembly
Clearance -78 process.
2) Painting introduced for exposed machined
Process and Final 8 surfaces in BEML HDT engine at final dispatch.
1 MYSORE HARIKRISHNAN 6 4
assembly Audit-5 3) Packing of ERCH unit improved with Separate
box.
PDO Rejection in SAP - 4) In BEML HDT BSII 8X8 Engine, torque trend is
14 Parts less at 800rpm. Improved the torque value at
800 rpm in coordination with D&D and
BOSCH. To eliminate test bed rework and FIP
tampering issues.
 STATUS OF TPIA INSPECTION – INHOUSE - MYSORE
In-house inspection Assembly
May’21-Nov’21

No of engines Feed Significant improvements / Assignments

Sl.No Location Inspector inspected Observations backs Resolved

1. Oil tube (HDT) tip leakage issue solved.

1 Assembly Rajvardhana
2. In 140 series, Tension pulley grease leak under study.
New Metal seal bearing received trials under process.
3. Filter head plug thread marks noticed during the
assembly of filter head. Where chances of
Filtered & un-filtered oil can mix Feed back sent to
D&D Request for correction in the Plug. Alternatively
use the sensor oil filter.(51z5180736)
4. Fuel line bending problem ,oil tubes, fuel tube ,HP
lines ,compressor return and supply tubes and feed
back sent to concerned department .
5. Following part number s drawings modified to improve
180 - 10 8 bending:
6. 130076633554,130076634004,*6634854,*6632144.
7. Modified drawings of Part number 130076633214,
224 fuel supply tubes are fitted on the engine , we
noticed the bending and height variation problem,
feed back given to D&D
8. BEML HDT Engine ECR (Engine Component Record)
updating and extraction from SAP.
9. BL9H oil cooler assembly leak test conducted and
monitoring.
10. Peripheral bolt auditing carried out for 170 Series and
monitoring.
 STATUS OF TPIA INSPECTION – INHOUSE - MYSORE
In-house inspection-Assembly Dec’21 – JAN 22

No of
Observatio Significant improvements / Assignments
Sl.No Location Inspector engines Feed backs Resolved
inspected ns

1. Oil tube (HDT) tip leakage issue solved.

1 Assembly Rajvardhana
2. In 140 series, Tension pulley grease leak under study. New Metal
seal bearing received trials under process.
3. Filter head plug thread marks noticed during the assembly of
filter head. Where chances of Filtered & un-filtered oil can
mix Feed back sent to D&D Request for correction in the Plug.
Alternatively use the sensor oil filter.(51z5180736)
4. Fuel line bending problem ,oil tubes, fuel tube ,HP
lines ,compressor return and supply tubes and feed back sent to
concerned department .
5. Following part number s drawings modified to improve bending:
6. 130076633554,130076634004,*6634854,*6632144.
7. Modified drawings of Part number 130076633214, 224 fuel
314 - 34 20 supply tubes are fitted on the engine , we noticed the bending
and height variation problem, feed back given to D&D
8. BEML HDT Engine ECR (Engine Component Record) updating and
extraction from SAP.
9. BL9H oil cooler assembly leak test conducted and monitoring.
10. Comparison b/w HDT BSII and BSIII critical parts displayed in
assembly for easy identification and better understanding .
11. HP line bending problem reported from assembly feed back given
to vendor, vendor visited firm after modification fresh batch
received. After fitment of modified HP line minor correction
required for tube 1,2&4, remaining tube fitment found
satisfactory.
12. Fuel supply tube bending problem modified tubes are fitted
engine, 130076633234,214 found satisfactory and
130076633224minor corrections required.
 STATUS OF TPIA INSPECTION – INHOUSE - MYSORE
In-house inspection Assembly
May 2021 to JAN 2022

Details Of Receiving Stores Inspection Data Of Month Wise

Details Of Two Inspectors

May June July Aug Sep Oct Nov DEC JAN

Months

Inspecte
36 70 105 126 20 40 64 70 72
d

Accepte
35 64 94 104 15 39 49 55 58
d

rejected 01 6 11 22 5 01 15 15 12
Mandatory conditions to be implemented at suppliers works.
1.100% inspection to be carried for New development parts all the parameters
(Dimensional, metallurgical, Heat treatment process, surface coating details etc.)
and record to be submitted before bulk supply.
 
2. Tatra/HDT component suppliers to inform BEML source inspection team (SIT) /
TPIA for inspection and clearance for all the supplies.
 
3. Pressure Test to be carried out for all casting after complete machining.

4. Interference fixture for all machined casting parts.

 
5. Interference fixtures to all metal tubes and pipes.
 
6. `Go” / `No Go’ plane plug / ring gauges to conform geometry and dimensional
accuracy of critical surfaces to its full length for machined components.
Mandatory conditions to be implemented at suppliers works.

7. Cpk = 1.33 min for machined critical dimensions to be maintained and records
to be attached in every batch of supply. 
 
8. Supply of Warranty parts (Performance related) and shelf life items should
be from latest manufacturing date only. Should not be older than fifteen
days wherever the warranty begins from MFD date on component Name plate .
 
9. Packing tubular items having brazing joints to be packed individually with
suitable supports to retain the pipe bending shape.
 
 
The above conditions are apart from regular inspection procedure.
 
 Following are the requirements for verification of casting quality and documents
links in suppliers’ reports.
 
1. DC No. or Invoice No. to be incorporated in your reports.
 
2. Record heat Nos. and corresponding quantity, Part number, part name in the reports.
 
3. Once in six month or for every 100th piece (Cylinder heads) and every 50th piece for
Cylinder block, Fly wheel hsg, gear case, gear case cover , oil cooler hsg & covers etc -
castings lay out to be made and report to be forwarded to division.
 
4. Tensile bar (Machined) to be provided once in six months for re verification at our
laboratory.
 
5. To confirm and document, weight of the castings, once in six months needs to
be measured and record to be provided.

Note: For easy tracking January and July of every year shall be identified for verification
and reports submission.
 
Thank You