RV3 KOEL Quality Issue- SRF Action... Plan 14 08 15 a

Shriram Foundry Ltd. Kolhapur, India.
Zanvar Group of Industries
1
ACTION PLAN FOR RECENT QUALITY
ISSUE OBSERVED AT KOEL KAGAL IN
MONTH OF JULY 2015.

2
Action plan & effectiveness
KOEL – Crank Case

3
Defect
Problem – Sand wash/inclusion at drag side body & oil gallery.

4
1) Found weak sand at ingate from core area.
2) Mould erosion found at pouring bar & runner bar.
3) Sand drop near side core touch prints. (Gear end & flywheel end area)
ACTION PLAN:-
1) Fillet radius at ingate from core. (dtd. 19/07/15)
2) Special sand used near pouring bar & runner bar. (dtd. 19/07/15)
3) Shell core provided for runner bar to avoid green sand erosion. (10 nos. Samples dtd. 28/07/15)
4) Additional gas vents provided at 4 places. (dtd. 19/07/15)
5) Gear & flywheel end cores prints to extended by 40 mm. ( dtd.- 5/08/15)
6) 2 nos. Gas vents at gear end & height & dia. increased.
7) 3 nos. gas vents crank case bore & height increased.
ROOT CAUSE ANALYSIS :-
Defect-: - Pin holes, Sand wash/inclusion at drag side body & oil gallery.

Gas vent height increased up to
Mould box height. Dtd. 28/07/15
Gear end & flywheel end
gas vent height increased
up to Mould box height.
Dtd. 13/08/15

6
Side prints extended by
40 mm. Targeted core
wt. increased 3.8 kg.
Gear & flywheel end cores prints extended by 40 mm. (dated- 5/08/15)
To avoid sand drop.

Monthly production
7
0
200
400
600
800
1000
1200
1400
1600
1800
348 386
983
1196
1294
1474
1605
ProductionQty.
Month
Foundry total production Qty.
Total production
Qty.
0
200
400
600
800
1000
1200
1400
473
569
809
1017
1269
991
1300
ProductionQty
Month
Machine shop total production Qty.
Total production Qty.
0
200
400
600
800
1000
1200
1400
535
192
865
1034
1387
1067
1289
TotaldispatchQty.
Month
Machine shop total dispatch Qty.
Total dispatch Qty.

8
Monthly rejection
22.6
15.6
19.11
11.96
11.14
10.14
11.27
7
0
5
10
15
20
25
Jan-2015 Feb-15 Mar-15 Apr-15 May-15 Jun-15 Jul-15 Aug 15-till date
Total rejection %
Series1

9
10.94
5.72
0
2
4
6
8
10
12
Foundry stage
rejection % July 2015
Total Rejection %
Rejection before & after cut off date – 14/07/15
Before cut off
date
After cut off
date
2.4
2.52
1
1.2
1.4
1.6
1.8
2
2.2
2.4
Machine shop
stage rejection % July 2015
Total rejection %
13.34
8.24
Total rejection %
July 2015
Total rejection %

10
Part Name: RV3 Crank-Case
Part No :- 39.185.01.0.00
CUSTOMER REPORTED PROBLEM -:

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Customer Name KOEL
Product Name & Part No.
RV3 Crank-Case 39.185.01.0.00
What Happen ? Thrust Cap Width observed undersize i.e.29.74 against 29.81
Why it is a Problem? Pl. refer next slide
When did it happen? 15/07/2015
Where it has been detected? KOEL Receipt QA
Who has detected it? KOEL Receipt QA
How it has been detected? During Inspection with Micrometer
How many detected? 1 Nos. in batch of 48 Nos.
Recurrence YES
Identify The Problem
Defect-: Thrust BRG cap width specified 29.81 to 29.84mm &
observed o/s & u/s

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ROOT CAUSE ANALYSIS:-
This is machine Aging effect. Thrust cap width observed o/s due to surface grinder table taper
within 0.030 to 0.120mm (total bed taper is within 0.04 to 0.40mm) & size not maintained
within given allowance.
SHORT TERM ACTION PLAN:-
For time being we had taken additional 0.250mm Magnetic table cut to reduce the taper of
bed. Also KOEL has given deviation within 29.76 to 29.84mm considering condition of machine
& bed taper. So It has been decided to maintain the size as per deviation received from KOEL
until New machine not received for MB cap grinding operation & which is permanent action to
eliminate this quality issue.
PERMENANT ACTION PLAN:-
KOEL has sanctioned the requirement for replacement of grinding machine. Thus Alka engg.
has obtain quotation for New Vertical surface grinder from supplier suitable to this component
& had forwarded to KOEL for further clearance. Awaited for KOEL reply on this.
Defect-: Thrust cap width specified 29.81 to 29.84mm &
observed o/s & u/s

INSPECTION METHOD IMPROOVED.:--
1)Provided Digital Micrometer to grinder operator at work station
2) instruction given to operator to check the size at three points where thrust
washer rest.
3) Also provided Special Dial type user friendly Gauge in order to get
simplicity into inspection method.
Defect-: Thrust cap width specified 29.81 to 29.84mm & observed o/s
& u/s
Digital Micrometer Spl. Dial Type GaugeAnalog Micrometer
PLANNED ACTION STATUS:- COMPLETED ON JUN 15 1st. WEEK

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Customer Name KOEL
RV3 Crank-Case 39.185.01.0.00
What Happen ?
LOP Cap Ø12 mm dowel hole depth observed plus
Where it has been detected? KOEL
Who has detected it? KOEL Assembly
How it has been detected? During Fitment of Lub oil Pump
How many detected? 01 Nos.
Recurrence No
Defect-: BRG Cap Ø12 mm dowel hole depth observed plus

15
This operation we are doing manually on Conventional RDM. And due to negligence job
passed to customer end . For inspection only plug gauge is available at work station to check
the size. Depth gauge is not available.
ACTION TAKEN:-
We have provided Plug cum depth gauge at work station to ensure the diameter as well as
depth of Ø 12 mm dowel hole.
Defect-: LOP Cap Ø12 mm dowel hole depth observed plus

16
Customer Name KOEL
RV3 Crank-Case 39.185.01.0.00
What Happen ? LOP Cap Ø12 mm dowel hole Centre distance Mismatch
Where it has been detected? KOEL
Who has detected it? KOEL Assembly
How it has been detected? During Fitment of Lub oil Pump
How many detected? 02 Nos.
Recurrence No
Defect-: BRG Cap Ø12 mm dowel hole Centre distance Mismatch

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We are performing this operation manually on conventional RDM. And this may be
happened due to drilling jig plate not placed properly into location main Bore
because operator has not cleaned the Jig plate & crankcase face
ACTION TAKEN:-
Earlier we had provided brush to clean the drilling Jig & Crankcase . Awareness
increased of operator by the forum of standing meeting at work station.
Defect-: LOP Cap Ø12 mm dowel hole Centre distance Mismatch

Thank you
18

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