1. Tube liquid Service valve core pin not functioning
Sunchirin Auto parts India Pvt. Ltd.
Investigation Report

2. Tube Liquid Service valve core pin concern
General Information
1. Part No: xxx
2. Part Name: Tube Liquid
3. Date Of Occurrence: 7th
Aug 2014
4. Discovered Location: xxx
5. Found at: Vehicle Assembly
6. NC Type: Core pin not functioning
7. NC Qty:01
8.Shop order no : Not available
EFECTIVE PART INFORMATION:
NC Part
1.Leak test check mark
2.Cap confirmation check mark (fitting, flange fitting, flange
pressure switch seating area & CV cap confirmation )
3.Deburing confirmation check mark
4.Confirming No core bend
Visual check marks availability in claim part

3. Claim part Filler rod dimension analysis
DEFECTIVE PART INVESTIGATION (1):
CLAIM PART
6.0
2.3
2
1.03
5.9
2.4
2
1.0
Filler rod
deposition
on threads
Tube Liquid Service valve core pin concern

4. . DEFECTIVE PART INVESTIGATION (2):
Comparison between Claim part & OK part
Observations
1.Even Gap found both sides between pipe to service valve
2.No excessive metal flow.
Observations
1.Gap observed between pipe to service valve
2.Excessive metal flow from the abnormal gap.
3.Effective thread mating length is 2.3mm only.
4.Claim condition Core height is 5.47mm only.
Minimum gap
Abnormalgap
Tube Liquid Service valve core pin concern

5. II. CAUSE OF OCCURRENCE
Bending
Drill hole & Deburring
Service valve brazing
Connector Brazing
Hot air blow
Core insertion
O-Ring insertion
Water leak test
Final Inspection
Packing & Delivery
OCCURRENCE
Defect PROCE
SS
CAUSE/
SUSPECT
CURRENT
CONTROL
CHECK
RESULT
JUDGE
MENT
PROBLEM
POINT
Brazing
metal over
flow inside
the service
valve
Service
valve
brazing
1)Insufficient
butting during
Toggling
2).Excessive filler
rod given by
operator
3) Not follow WI
(Sudden
Quenching,)
3a) Not Follow
WI (Gap
presence)
1).Toggle and
Profile jig
control
2).Rod
bending jig
3)Cool air
Timer with
yellow light
indicator
3a)Visual
1).Gap between
pipe to Service
Valve
2) Abnormal
Inner flow
inside the SV
3).Abnormal
inner flow
3a) Gap
between pipe to
Service Valve
X
X
X
X
1).Inner flow from
the Gap
2). Core stuck
inside charge
valve
3) Core stuck
inside charge
valve
Excess Filler
material flow
inside the Service
valve from the gap
Core Malfunctioning
MACHINE
Gap created b/w pipe &
Service Valve
MAN
MATERIAL METHOD
Not follow SOP / WI
(Abnormality Action Flow &
Brazing WI)
Excess filler rod given by
operator
Tube Liquid Service valve core pin concern

6. III. MECHANSIM OF DEFECT –OCCURRENCE
NOTE:
When there is no gap b/w pipe to Service valve
required fillet radius will be formed by using
standard Filler rod length.
NO GAP
REQUIRED FILLET RADIUS
FORMED
Condition:
Rod Length is 16mm
Result
Actual usage length
R1.94
Tube Liquid Service valve core pin concern

7. III(A). MECHANSIM OF DEFECT –OCCURRENCE
Cause of Occurrence :
Due to gap between Pipe to Service Valve,
excess filler metal given by the operator during
brazing due to no formation of Fillet.
SAPI conducted Simulation test to confirm this defect occurred due to
excess filler metal given by the operator, since there is a gap created
between the Pipe to Service valve .
GAP LESS FILLET
Condition:
Rod Length is 16mm
Actual usage length
Result
R0.8
Tube Liquid Service valve core pin concern

8. Std. Continuity
pin length
Condition
Filler rod
length
Sample Remarks
9.05
1). Brazing filler rod length 20mm
2).Brazing holding pin tip Ø 4.5 (As per
last corrective action)
3).Pipe to SV gap while brazing
20mm
1)Part got rejected due to no thread available to
tighten the Core Pin.
2)Operator faced difficulties to remove the part
from the jig.(Because pin tip hold the SV after
brazing)
9.05
1). Brazing filler rod length 18mm
2). Brazing holding pin tip Ø 4.5 (As
per last corrective action)
3).Pipe to SV gap while
brazing
18mm
1)Continuity test pin detect the presence of inner
flow & rejected the part.
2)Filler metal accumulated beneath the threads
and over the threads as well.
3)Operator faced difficulties to remove the part
from the jig.(Because pin tip hold the SV after
brazing)
9.05
1). Brazing filler rod length 17mm
2). Brazing holding pin tip Ø 4.5 (As
per last corrective action)
3).Pipe to SV gap while brazing
17mm
1)Continuity test pin detect the presence of inner
flow & reject the part.
2)Filler metal accumulated beneath the threads
and over the threads as well.
9.05
1). Brazing filler rod length 16mm
2). Brazing holding pin tip Ø 4.5 (As
per last corrective action)
3).Pipe to SV gap while brazing
16mm
1)Continuity test pin will pass the part as OK.
2) Filler metal accumulated beneath the threads
& over the last two threads.
3)Operator got no problem in removing the part
from the jig.
Tube Liquid Service valve core pin concern
IV. Simulation test for gap b/w Pipe to service valve with different filler rod length
Observation:
1. From the above simulation test we noticed, Inner flow happening is due to excessive rod usage.
Conclusion:
By closing the gap between Pipe to Service valve in order to control excessive filler rod usage by the operator.

9. SL.NO Condition Filler rod length Sample Remarks
1
1). Brazing filler rod length 24mm
2).Brazing holding pin tip Ø 4.5
(As per last corrective action)
3).Pipe to SV gap while
brazing
24mm
1)Inner flow observed
2) Continuity test PASS
3) Core height test PASS
2
1). Brazing filler rod length 22mm
2).Brazing holding pin tip Ø 4.5
(As per last corrective action)
3).Pipe to SV gap while
brazing
22mm
1)Inner flow observed
2) Continuity test PASS
3) Core height test PASS
3
1). Brazing filler rod length 20mm
2).Brazing holding pin tip Ø 4.5
(As per last corrective action)
3).Pipe to SV gap while
brazing
20mm
1)Inner flow observed
2) Continuity test PASS
3) Core height test PASS
4
1). Brazing filler rod length 18mm
2). Brazing holding pin tip Ø
4.5 (As per last corrective action)
3).Pipe to
SV gap while brazing
18mm
1)Inner flow observed
2) Continuity test PASS
3) Core height test PASS
5
1). Brazing filler rod length 16mm
2). Brazing holding pin tip Ø 4.5 (As
per last corrective action)
3).Pipe to SV gap while brazing
16mm
1)Inner flow observed
2) Continuity test PASS
3) Core height test PASS
Tube Liquid Service valve core pin concern
V. Simulation test for gap b/w Pipe to service valve with different filler rod length (Water sudden Quenching.)
Conclusion:
Due to sudden Water Quenching filler material deposition was improper (Thermal changes).

10. SL.NO Condition Filler rod length Sample Remarks
6
1). Brazing filler rod length 28mm
2).Brazing holding pin tip Ø 4.5
(As per last corrective action)
3).Pipe to SV gap while
brazing
28mm
1)Inner flow observed
2) Continuity test Detected.
3) Core height test Detected.
7
1). Brazing filler rod length 30mm
2).Brazing holding pin tip Ø 4.5
(As per last corrective action)
3).Pipe to SV gap while
brazing
30mm
1)Inner flow observed
2) Continuity test Detected.
3) Core height test Detected.
8
1). Brazing filler rod length 32mm
2). Brazing holding pin tip Ø
4.5 (As per last corrective action)
3).Pipe to
SV gap while brazing
32mm
1)Inner flow observed
2) Continuity test Detected.
3) Core height test Detected.
Tube Liquid Service valve core pin concern
V (A). Simulation test for gap b/w Pipe to service valve with different filler rod length Water sudden Quenching.)
Observation:
Filler metal deposition was not uniform but close to the defective sample. From the previous slide we observed till
24mm filler rod Core insertion machine PASS the part as OK but above 24mm it was detecting as NG part.
Conclusion:
Since Deposition of Rod during sudden quenching the results are varying. Under sudden quenching as we couldn't
predict the molten metal deposition inside the Service valve. So avoid sudden Quenching.
AllThreeSamplesareVerymuch
ClosetotheDefectiveSample.

11. Tube Liquid Service valve core pin concern
BEFORE AFTER
No additional clamp
Additional clamp provided to avoid gap b/w Pipe
to Service valve
VI. CORRECTIVE ACTION –OCCURRENCE (To Close the Gap)
SAPI conducted Re occurrence test for Corrective Action taken (Close the Gap).
VI (A). CORRECTIVE ACTION –OCCURRENCE (Not follow WI- Avoid Sudden Quenching & Gap).
1. Replacing the current Yellow color indicator by rotating beacon with buzzer after brazing for cooling.
PIC: Maintenance Due date: 23.09.2014
2 Revising the current WI with above pictorial information . PIC: Team Leader. Due date: 20.09.14
3 Reeducate the Brazers to inform superior in case of abnormality found Like Gap etc. PIC: Team Leader Due: 18.09.14
VI (B). CORRECTIVE ACTION –OCCURRENCE (Excessive Rod given).
1. Propose to modify the current bending rod jig by Indentation mark type of Jig to make sure required
rod length maintained.
2 Training to be provided to the concerned Brazers based on Simulation test Samples.
PIC: Team Leader Due Date: 18.09.14
3 Preparing Limit sample for Fillet Radius at No gap condition for operator better understanding. PIC: TL Due: 25.09.14

12. SL.NO Condition Filler rod length Sample Remarks
1
1). Brazing filler rod length 20mm
2).Brazing holding pin tip Ø 4.5 (As
per last corrective action)
3).Pipe to SV no gap while brazing
24mm
Excess filler rod flowed outside the service
valve due to no gap
2
1). Brazing filler rod length 20mm
2).Brazing holding pin tip Ø 4.5 (As
per last corrective action)
3).Pipe to SV no gap while brazing
22mm
Excess filler rod flowed outside the service
valve due to no gap
3
1). Brazing filler rod length 20mm
2).Brazing holding pin tip Ø 4.5 (As
per last corrective action)
3).Pipe to SV no gap while brazing
20mm
Excess filler rod flowed outside the service
valve due to no gap.
4
1). Brazing filler rod length 18mm
2). Brazing holding pin tip Ø 4.5
(As per last corrective action)
3).Pipe to SV no gap while brazing
18mm
Excess filler rod flowed outside the service
valve due to no gap.
Filler rod deposition is less than the previous
cause.
5
1). Brazing filler rod length 17mm
2). Brazing holding pin tip Ø 4.5 (As
per last corrective action)
3).Pipe to SV no gap while
brazing
17mm
There is no outer flow.
6
1). Brazing filler rod length 16mm
2). Brazing holding pin tip Ø 4.5 (As
per last corrective action)
3).Pipe to SV no gap while
brazing
16mm
There is no outer flow.
Results of Item # 6 Simulated part
Continuity was OK because there was
no inner flow
Tube Liquid Service valve core pin concern
VII. Re occurrence test for no gap b/w Pipe to service valve with different filler rod length (Outer flow cond.)
Conclusion:
If excess filler rod given when there is no gap condition, filler rod will flow outside the service valve.
R1.24-1.88
R0.8-1.77
R1.04-2
R 1.55-2.5
R1.07-1.09
R1.06-1.08

13. SL.NO Condition Filler rod length Sample Remarks
1
1). Brazing filler rod length 24mm
2).Brazing holding pin tip Ø 4.5
(As per last corrective action)
3).Pipe to SV no gap while
brazing
24mm
1)No inner flow observed
2) Continuity test pin PASS
3) Core height test PASS
2
1). Brazing filler rod length 22mm
2).Brazing holding pin tip Ø 4.5
(As per last corrective action)
3).Pipe to SV no gap while
brazing
22mm
1)No inner flow observed
2) Continuity test pin PASS
3) Core height test PASS
3
1). Brazing filler rod length 20mm
2).Brazing holding pin tip Ø 4.5
(As per last corrective action)
3).Pipe to SV no gap while
brazing
20mm
1)No inner flow observed
2) Continuity test pin PASS
3) Core height test PASS
4
1). Brazing filler rod length 18mm
2). Brazing holding pin tip Ø
4.5 (As per last corrective action)
3).Pipe to
SV no gap while brazing
18mm
1)No inner flow observed
2) Continuity test pin PASS
3) Core height test PASS
5
1). Brazing filler rod length 17mm
2). Brazing holding pin tip Ø 4.5 (As
per last corrective action)
3).Pipe to SV no gap while
brazing
17mm
1)No inner flow observed
2) Continuity test pin PASS
3) Core height test PASS
6
1). Brazing filler rod length 16mm
2). Brazing holding pin tip Ø 4.5 (As
per last corrective action)
3).Pipe to SV no gap while
brazing
16mm
1)No inner flow observed
2) Continuity test pin PASS
3) Core height test PASS
Tube Liquid Service valve core pin concern
VII (A). Re occurrence test for no gap b/w Pipe to service valve with different filler rod length (outer flow’s inner cond.)
Conclusion:
UnderNOGAPconditionifexcessivefillerrodappliedthefillermaterialwill
flowoutsideoftheCVbodywhichcanbevisuallyidentified

14. Tube Liquid Service valve core pin concern
VIII. CAUSE OF NON DETECTION
Bending
Drill hole & Deburring
Service valve brazing
Connector Brazing
Hot air blow
Core insertion
O-Ring insertion
Water leak test
FI
Packing & Delivery
Core
Malfunctioning
MACHINE
Current mechanism
can’t control the
Continuity Pin length
/ Under size
MAN
MATERIAL
METHOD
Defect PROCESS CAUSE/
SUSPECT
CURRENT
CONTROL
CHECK
RESULT
JUDGE
MENT
PROBLEM
POINT
Inner
flow not
detected
Core
insertion
Continuity pin
length
Undersize
2. Bypass /
Intentional
3. Aluminum
Pin Thread
worn out
Continuity test
pin
Use Bypass
Key incase of
abnormity
found by
superior only.
Set continuity
test pin length
at 9.05mm by
tightening the
Pin thread
with SS Nut
Core pin
plunger not
reached until
it’s maximum
travel distance.
(i.e. 9.05mm)
Operator
misuse the
Key.
Continuity test
Pin length
varying from
9.05 to 8.29mm
X
X
X
Ac Leak during
charging
Defect part
reached to
Next process
Core pin
plunger not
reached until
it’s maximum
travel distance
Ship out
Less strengthen
material
Misuse the
Bypass Key

15. Tube Liquid Service valve core pin concern
IX. MECHANSIM OF DEFECT – NON DETECTION
Cause of Non Detection :
Current Continuity test pin under size
(Below 9.05mm)
Why test pin under size?
Due to continuous usage of Continuity Pin,
the threads worn out which causes pin
length under size from its standard length
CONTINUTY TEST HOLDER & PIN CHARGE VALVE INSERTION
CONTINUITY TEST
DEVICE HOLDER
CONTINUITY TEST
DEVICE PIN
PLUNGER
TRAVELLIN
G DISTANCE
CORE PIN
SERVICE VALVE
AFTER PIN PRESS
SAPI conducted Simulation test to confirm the Non detection occurred due to varying Pin length.

16. Tube Liquid Service valve core pin concern
IX (A). MECHANISM OF CORE PLUNGER MOVEMENT
OK Part- Core Seating
condition
Claim Part – Core Seating
condition
Claim part –Continuity
test with Std. pin length
(9.05)
Claim part –Continuity
test with Undersize pin
length (8.29)
Observation :
1. Effective Thread
seating length is 3.75mm
2. Core height in normal
condition is 6.96.
Observation :
1. Effective Thread
seating length is only
2.3mm
2. Core height with claim
condition is 5.47
Observation :
1. Effective Thread
seating length is only
2.3mm
2. Max. plunger travelling
distance with Std. pin
length is 8.17.
3. Core height with claim
condition is 5.47 which is
below the spec.
Observation :
1. Effective Thread
seating length is only
2.3mm
2. Max. plunger travelling
distance with under size
pin length is 7.41
3. Core height with claim
condition is 5.47 which is
below the spec.
Std. Core Height: 6.6 ± 0.5
Conclusion:
According to the above observation it is very clear that if Continuity test skip the defect part but still it hold in
the next process i.e. Core height detection. Since this problem is skipped to customer end suspected it as either
Bypass or Intentionally. (No Traceability number found on defective part)

17. Tube Liquid Service valve core pin concern
Continuity pin length Condition
Standard filler rod
Length
Sample Remarks
9.05mm
1). Brazing filler rod
length 16mm
2).Pipe to SV gap while
brazing
16mm
1)Continuity pin detect the
presence of inner flow
2)Filler metal accumulated
beneath the threads and upon
threads also
8.8mm
1)Continuity pin not detect
the presence of inner flow
2)Filler metal accumulated
beneath the threads and upon
threads also
3) Core Height Failed
8.5mm
1)Continuity pin not detect
the presence of inner flow
2)Filler metal accumulated
beneath the threads and upon
threads also
3) Core Height Failed
8.2mm
1)Continuity pin not detect
the presence of inner flow
2)Filler metal accumulated
beneath the threads and upon
threads also
3) Core Height Failed
X. Simulation test for Various Continuity test pin length
Observation:
1. From the above simulation test we noticed, Inner flow can not be detected if the Pin length is lesser than the
Standard.
Conclusion:
By maintaining the Standard continuity test Pin length defect can be detected.

18. BEFORE AFTER
Tube Liquid Service valve core pin concern
Observation:
1.More clearance observed between Holder
(Top) base to Pin base which result in Pin
length variation due to upward motion.
2.SS nut using for tightening the Aluminum
Fine thread which causes thread worn out.
Observation:
1.Close gap observed between Holder (Top)
base to Pin base as such there is no room for
Pin to move upwards.
2.SS nut using for SS Fine thread tightening.
Conclusion:
By Closing the Clearance between Holder (top) base to Pin base & changing Pin material from
Aluminum to SS will result in Non variable continuity test pin length.
XI. CORRECTIVE ACTION –NON DETECTION (Continuity pin length undersize due to thread worn out )
(0.3mm)

19. Tube Liquid Service valve core pin concern
XI (A). CORRECTIVE ACTION –NON DETECTION (Continuity pin length undersize due to thread worn out )
Continuity Pin length increased by 0.3mm in order to close the Gap between Holder
(Top) base to Pin base.

20. Tube Liquid Service valve core pin concern
XII. RE OCCURRENCE TEST–NON DETECTION
Reoccurrence test:
Standard Continuity pin length -9.05mm
Varying Continuity
pin length
Sample-01 Sample-02 Sample-03 Conclusion
9.05mm Inner flow detected Inner flow detected Inner flow detected OK
8.8mm Inner flow not detected Inner flow not detected Inner flow not detected
Inner flow can not be
detected if the Pin length
is lesser than the
Standard..
8.5mm Inner flow not detected Inner flow not detected Inner flow not detected
8.2mm Inner flow not detected Inner flow not detected Inner flow not detected
Additional corrective action taken:-
1. Introduced Pin length inspection on weekly basis through TPM check sheet . PIC: EFC Team leader. Due date:
Completed.

21. KL446240-4400 Tube Liquid Service valve core pin concern
XIII. CORRECTIVE ACTION –NON DETECTION
1. Introducing Continuity test pin length inspection on daily basis through TPM Check sheet.
2. Rule to be created to keep the Bypass Key with Team Leader and Above, and that can be used
during abnormity found by above said people.

22. KL446240-4400 Tube Liquid Service valve core pin concern
XIII (A). CORRECTIVE ACTION –NON DETECTION (Continuity pin length undersize due to thread
worn out ) DAILY / WEEKLY TPM CHECK LIST
Section : Production Machine Name: Core Insertion
Month : Machine Number :
ITEM No. POINTS TO CHECK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Setting 1
Torque screw driver setting is 3.0
kgf/cm²
Pneumati
c
2 Air pressure 3 to 4 bar
3 Drain water particles from air filter
4 Check the rod less cylinder
General
5 Check the all sensors (13)
6 Check all indicator & Push button
7 Check the part counter
8 Check the core height tester
9 Check & clean the slide way
Weekly
10
Check the length of continuity pin
(min 9.05)
11
* Applay the greese for slideway &
rod less cylinder
*Check reverse torque 2.5 ~ 3.5
Kgf-cm
Signature
Confirm by set up
Points Problem may occur from equipment failure:
1 Gas leakage system failure
2 Chips remain inside the CV hole may block the system
3 During air blow water may enter into the CV hole leakage may not be detect
4 Conform the continity pin length (9.05)
FORMAT NO.F-M017 Revised Date:- 10-08-14, REV.NO.05
ACTION TAKEN: APPROVAL:
NOTE:
1.All the points to be check every morning before starting work
2.Where 'O' OK things are in good condition
3.Where ' ' needed adjustment
4.Where 'NG' things are not in good condion issue MMR
5.Record all adjustments and action for abnormality
6.Pressure reading must enter
*Indicates weekly check points
1
5
4
2&3
9&1
1
8
7
6
10
10

23. KL446240-4400 Tube Liquid Leak Claim
Sunchirin Auto parts India Pvt. Ltd.
END of
Investigation Report