Supplier Review Meeting-MACPL Dec-21.pptx

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1. ACTION PLAN FOR QUALITY ISSUE Supplier Name: M/S MARATHWADA AUTO COMPO PVT LTD Date: 19.12.2021

2. SUPPLIER PERFORMANCE: M/S MACPL

3. Vendor Name Material Description Total Rej. REJECTION TYPE Rejection Phenomenon Dimensional Aesthetic PART & DEFECT WISE DETAIL MACPL 550PC09807 UNDER BRACKET ASSEMBLY 1 1 SIDE BORE COUNTER DEPTH OVERSIZED 550PC10807 UNDER BKT.ASSY- DISCO H 2 2 BACK CHAMFER 2 X 10 MISSING 550PC10807 UNDER BKT.ASSY- DISCO H 3 3 PAINT PEEL OFF AT WELD RUN & UNCOVER F20502107B UNDER BKT.ASSY. - B104D 5 5 SIDE BORE PARALLELISM NOT OK F20504507B UNDER BKT ASSY B103 1 1 M10 COUNTER ID UNDERSIZED F20507307B UNDER BKT ASSEMBLY K-2015 130 130 POWDER COATING PAINT PEEL OFF F800500507 UNDER BRACKET ASSEMBLY 1 1 BACK CHAMFER MISSING F20510907B UNDER BRACKET ASSEMBLY K19 DRUM FF 10 10 SIDE BORE PARALLELISM NOT OK F800502607 UNDER BKT ASSY 2 2 SIDE BORE M10 THREAD NOT OK 550PC10807 UNDER BKT.ASSY- DISCO H 10 10 SIDE BORE PARALLELISM NOT OK F800510107 UND BKT DSVR 125 ST ( WITH MONOSHOX) 10 10 SHAFT PRESSING HEIGHT NOT OK F20510907B UNDER BRACKET ASSEMBLY K19 DRUM FF 5 5 SHAFT OD OVERSIZED F20502107B UNDER BKT.ASSY. - B104D FF 5 5 PAINT CHIP OFF AT WELD RUN F20510907B UNDER BRACKET ASSEMBLY K19 DRUM FF 50 50 SIDE BORE PARALLELISM NOT OK TOTAL 235 97 138

4. DEFECT PHENOMENA-WISE RECORD Part Name Defect Phenomena Apr-21 May-21 Jun -21 July-21 Aug-21 Sep-21 Oct-21 Nov-21 Remark B104 / DH/ JZ / K-19 SIDE BORE PARALLELISM NOT OK 162 30 20 5 70 K-1 / K-19 SIDE BORE ID OVERSIZED 5 1 CAL-115 M6 THREAD MISSING 1 K-70 ID UNDERSIZE ( WRONG SUPPY ) 100 K-1 / JD / DH/ B103/ K-2015 POWDER COATING PAINT PEEL OFF 51 130 K-2015 PAINT CHIP AT WELD RUN 5 K1 STEERING SHAFT OD UNDERSIZED 1 K-2015 PRESSING HEIGHT NOT OK 51 BM 150 / B103 PAINT PEEL OFF ISSUE- Q GAURANTY NOT RCD 300 K-2015 DIMN 2MM NOT OK & HANDLE TOUCH ISSUE IKM 50 K-2015 HANDLE GAP ISSUE-IKM RETURN PARTS 115 CAL-115 SIDE BOSS COUNTER DRILL CHAMFER MISSING 15 JD PAINT IN M10 SHAFT 1 DISCO- H DIMEN 4 MM UNDER SIZE 2 K-2015 ST. SHAFT O/D MACHINING STEP 1 CAL-115/ DH / K-1 BACK SIDE CHAMFER MISSING 1 3 BM150 SIDE BORE M10 THREADING NOT OK 2 JD SIDE BOSS COUNTER DRILL DEPTH O/S 1 2 K-19 SHAFT OD. OVERSIZE 5 JZ ST. SHAFT HEIGHT NOT OK 10 DISCO-H PAINT PEEL OFF AT WELD RUN 3   Total 168 100 353 195 40 143 92  

5. 1 PARALALISM NOT OK

6. DEFECT PHENOMENA DETAILS 6 ● Phenomenon : Parallality not ok ・ Supplier: . Marathwada Auto comp pvt ltd ・ Model: JD/Disco/JZ ● Parts Stock check results   NG Parts OK Parts   Area Total Stock Checked NG Status ETPL end 600 600 5 completed Warehouse Completed Transit   Completed MACPL end finish 450 450 6 completed WIP         ・ Parts No .: Parts name: Under Bkt assly JD/Disc/JZ ・ Date of Occurrence: 6.12. 2021 Prallality Not ok Parallality OK Part Spec - Parallality required 0.150 mm O bserved- 0.550 Mm

7. ACTION PLAN FOR Paralalisem not ok Detection Side Countermeasure Occurrence side countermeasure Manually Gauging prepared to check perpendicularity after pressing and welding. Awareness training given to pressing & welding operator through OPL Limit switch added in ram to have auto return stroke of ram by sensing shaft position after complete pressing. Manual error possibility eliminated completely. Parameter Specification Act. Observation Jud. Parallelism required 0.150 mm 0.550 mm Not Ok C’ Measure:- Problem Phenomenon : Total Qty. Ok Qty. NG Qty. 600 595 05 Part Name: UBA jd,dicoh &b104d Process Flow: Cause Verification & Fact Analysis: Parallelism Not ok Man M/c Material Method Sr. No Factor Possible Causes Verification Result 1 Man Unskilled operator Skill matrix verified & found ok for all pressing & welding stage operator   √ 2 Less awareness to operator Training records verified & found ok √ 3 Set up verification wrong As NG qty observed in single digit, we can conclude that there is no possibility of wrong set up approval. √ 4 Method Fixture block setting not ok Bolt setting to control the pressing height √ 5 Pressing setting not ok Manual adjustment of sensor to control stroke length resulting in Variation of pressing height during set up.   √ 6 Machine Incomplete stroke of Hy. ram Sensor available to control stroke length of ram √ 7 Hydraulic pressure not ok Pressure gauge available with shut off valve √ Power failure Machine will resume working from previous stop point- auto control √ 8 9 Malfunction of proxy sensor/ wrong setting of proxy sensor Sensor setting in manual so there is possibility of manual error X 10 Material Shaft length undersized In failed part shaft length found Ok.   √ 11 Shaft OD Oversized In failed part shaft OD found Ok.   √ Under Bracket ID undersized In failed part under bracket ID found Ok.   √ 12 Problem Analysis:   Why-1 Why-2 Why-3 Why4 Occurrence Side Shaft and forging Pressing not ok Perpendicularity found not ok with respective shaft Pressing plate bush resting area wear out Bush resting area wear out Detection Side Perpendicularity not ok Skipped from final inspection stage Sampling based inspection Type Of Phenomena New/Repeated If Repeated No. Of Occurrence   7 Parallelism Not ok Pressing Method Not ok Unskilled manpower Shaft length undersize 1-Receiving Mtl. 2- Buffing 3- Drilling 4- Rough Boring 5- Back side chmf 6- 5.1 Drilling 7- Boss Drilling 8 – M6 Boss Facing 9- Lug Milling 10- Slitting & Facing 11–Counter Drilling 12- Deburing Chmf . 13 – Pressing 14- Welding 15- welding buffing 16- P. Coating 17- Tapping 18- Fine Boring 19- F. Inspection Malfunctioning of proxy sensor- wrong sensor setting Fixture Block setting Not ok Set up verification wrong Incomplete stroke of hydraulic ram Hydraulic pressure not OK Power Failure Under bracket ID undersize Sheering Shaft OD Oversize

8. Photo Before After PRESSING PLATE TOP BOTTOM GRINDING DONE .AFTER CORRECTION PERPEDICULARITY READING CONSISTANCT.WITHIN 50 MICRON PRESSING BUSH RESTING AREA WEAR OUT PRESSING BUSH RESTING AREA WEAR OUT DUE TO THIS SHAFT &FORGING PERPENDICULARITY NOT CONSISTANT .MAX- 0.1 MM

9. HORIZENAL DEPLOYMENT After HORIZENALY ALL MODEL PRESSING PLATE TOP BOTTOM GRINDING DONE .

10. Photo Before After No any side boss resting stopper at fine boring fixture . After Provided side boss resting stopper at fine boring fixture. Horizontal deployment for other fixtures . 100% inspection doing at final stage by upper bkt c.d. gauge Provided New upper Bkt C.D Gauge & 100% parallelism checking at final stage

11. HORIZENALY ALL MODEL PRESSING PLATE TOP BOTTOM GRINDING DONE . INSPECTION METHOD CHENGE

12. After V-BLOCK ADDITION Modification in fine boring fixture

13. POWDER COATING PEELOFF PROBLEM 2

14. DEFECT PHENOMENA DETAILS Phenomenon : Paint peel Off ・ Supplier: . Marathwada Auto comp pvt ltd ・ Model: Under bkt Assly K-2015 ● Parts Stock check results   NG Parts OK Parts   Area Total Stock Checked NG Status ETPL end 150 150 130 Completed Warehouse Completed Transit   Completed MACPL end finish 50 50 50 completed WIP         ・ Parts No.: F20507307 ・ Parts name: UND BKT K-2015 ・ Date of Occurrence: 2 . 10. 2021 Paint peel off OK Part Spec - No Peel off Observed- Paint Peel Off

15. ACTION PLAN FOR Detection Side Countermeasure Occurrence side countermeasure Increase Adhesion test frequency , Four Times in shift Reject all Rusty material at inward stage & send back to party. Display SOP at inward stage. Parameter Specification Act. Observation Jud. Paint Peel off No Paint peel off Paint peel off Not Ok C’ Measure:- Problem Phenomenon : Total Qty. Ok Qty. NG Qty. 150 20 1 30 Part Name: UBA J D Process Flow: Cause Verification & Fact Analysis: Paint Peel off Man M/c Material Method Sr. No Possible Causes Verification Result 1 Unskilled Manpower skilled Manpower used   √ 2 Job Loading Job Loading Found OK √ 3 Job Handling Job Handling Found Not Ok √ 4 PT line Parameter PT Line Parameter Found Ok √ 5 Oven Temp . Drop Oven Tem . Found ok √ 6 Conveyor speed Conveyor speed found ok   √ 7 Inward Material Inward Material Found Rusty X 8 Phosphate Layer Phosphate Layer Found Not Ok X 9 Hanger Condition Hanger found clean √ 10 Basket condition Basket Found ok and clean.   √ Problem Analysis:   Why-1 Why-2 Why-3 Why4 Occurrence Side Paint Peel off Surface Addison not proper on Forging area Phosphating layer getting not ok Inward part condition found Rusty. Derusting process not available at Amulet coating Detection Side Paint peel off Sample Basis Inspection carried out powder coating lab. Type Of Phenomena New/Repeated If Repeated No. Of Occurrence   2 Tool Paint peel off Job Loading Job Handling Unskilled manpower Inward Material condition 1-Receiving Mtl. 2- Buffing 3- Drilling 4- Rough Boring 5- Back side chmf 6- 5.1 Drilling 7- Boss Drilling 8 – M6 Boss Facing 9- Lug Milling 10- Slitting & Facing 11–Counter Drilling 12- Deburing Chmf . 13 – Pressing 14- Welding 15- P. Coating 16- Tapping 17- Fine Boring 18- F. Inspection Oven temp, drop Hanger Condition 15 Conveyor speed Phosphate Layer Basket condition PT line Parameter

16. Photo Before Rusty Material Used for Powder Coating After OPL & SOP DISPLAY Check TTR found Ok Without Rusty material used for powder coating also check Adhesion test at MACPL end per lot Check adhesion test each lot at powder coating unit Check PT line Process Parameter & Maintain within range

17. Photo Suspected Qty. 73 nos. Check adhesion test at in-house & Powder coating plant Loading & Unloading SOP display Inward Inspection SOP Inward Inspection Report Start Sample Base Inspection

18. POWDER COATING PEELOFF PROBLEM 3

19. DEFECT PHENOMENA DETAILS Phenomenon : Paint peel Off on weld bid ・ Supplier: . Marathwada Auto comp pvt ltd ・ Model: Under bkt Assly k2015 & Disco H ● Parts Stock check results   NG Parts OK Parts   Area Total Stock Checked NG Status ETPL end 450 450 8 Completed Warehouse Completed Transit   Completed MACPL end finish 150 150 4 completed WIP         ・ Parts No .: ・ Parts name: UND BKT K-2015 , UND BKT, Disco H ・ Date of Occurrence : Paint peel off OK Part Spec - No Peel off Observed- Paint Peel Off

20. ACTION PLAN FOR Detection Side Countermeasure Occurrence side countermeasure Increase Adhesion test frequency , Four Times in shift Reject all Without buffing material at inward stage & send back to party. Parameter Specification Act. Observation Jud. Paint Peel off No Paint peel off Paint peel off Not Ok C’ Measure:- Problem Phenomenon : Total Qty. Ok Qty. NG Qty. 450 442 8 Part Name: UBA K2015 & Disco-H Process Flow: Cause Verification & Fact Analysis: Paint Peel off Man M/c Material Method Sr. No Possible Causes Verification Result 1 Unskilled Manpower skilled Manpower used   √ 2 Job Loading Job Loading Found OK √ 3 Job Handling Job Handling Found Not Ok √ 4 PT line Parameter PT Line Parameter Found Ok √ 5 Oven Temp . Drop Oven Tem . Found ok √ 6 Conveyor speed Conveyor speed found ok   √ 7 Inward Material Inward Material Found without buffing X 8 Phosphate Layer Phosphate Layer Found Not Ok X 9 Hanger Condition Hanger found clean √ 10 Basket condition Basket Found ok and clean.   √ Problem Analysis:   Why-1 Why-2 Why-3 Why-4 Why-5 Occurrence Side Paint Peel off on weld bid Surface Addison not proper on weld bid area Phosphating layer getting not ok Inward part condition found without buffing . Buffing process missing Detection Side Paint peel off Sample Basis Inspection carried out powder coating lab. Type Of Phenomena New/Repeated If Repeated No. Of Occurrence   3 Tool Paint peel off on weld bid Job Loading Job Handling Unskilled manpower Inward Material condition 1-Receiving Mtl. 2- Buffing 3- Drilling 4- Rough Boring 5- Back side chmf 6- 5.1 Drilling 7- Boss Drilling 8 – M6 Boss Facing 9- Lug Milling 10- Slitting & Facing 11–Counter Drilling 12- Deburing Chmf . 13 – Pressing 14- Welding 15-Welding Buffinng 16- P. Coating 17- Tapping 18- Fine Boring 19- F. Inspection Oven temp, drop Hanger Condition 20 Conveyor speed Phosphate Layer Basket condition PT line Parameter

21. Photo Before Without buffing Material Used for Powder Coating After OPL & SOP DISPLAY With buffing material used for powder coating also check Adhesion test at MACPL end per lot

22. 4 Back side 10 º chamfer missing .

23. 5 Side bore m10 threading not ok

24. COUNTER DRILL DEPTH NOT OK 6

25. DEFECT PHENOMENA DETAILS Phenomenon : Counter drill Depth Not Ok ・ Supplier: . Marathwada Auto comp pvt ltd ・ Model: Under bkt Assly JD ● Parts Stock check results   NG Parts OK Parts   Area Total Stock Checked NG Status ETPL end 250 249 1 Completed Warehouse Completed Transit   Completed MACPL end finish 100 100 completed WIP         ・ Parts No.: 550PC09807 ・ Parts name: UND BKT JD ・ Date of Occurrence: 01 . 10. 2021 Counter Drill Depth Not Ok OK Part Spec - Counter Drill Depth 20.5 mm Observed- Counter drill depth 23 mm .

26. ACTION PLAN FOR Detection Side Countermeasure Occurrence side countermeasure Provided new depth gauge with at final & Machining stage and increase inspection frequency Provided new stopper on counter drill m/c. and stopper changing frequency is added in PM plan. Parameter Specification Act. Observation Jud. Side bore counter depth 20.5 ±0.5 23 Not Ok C’ Measure:- Problem Phenomenon : Total Qty. Ok Qty. NG Qty. 25 249 1 Part Name: UBA J D Process Flow: Cause Verification & Fact Analysis: Counter Drill Depth Not ok Man M/c Material Method Sr. No Possible Causes Verification Result 1 Unskilled Manpower skilled Manpower used   √ 2 Job Loading Job Loading Found OK √ 3 Job Handling Job Handling Found Not Ok √ 4 Job clamping Job Clamping found ok √ 5 Spindle run out Spindle run out found ok   √ 6 Stopper Setting Stopper setting not ok X 7 Drill length U/s Drill length found ok. √ 8 Fixture cullet ware out Fixture collet found Ok √ 9 Inward material condition Inward material condition found ok   √ Problem Analysis:   Why-1 Why-2 Why-3 Why4 Occurrence Side Counter Drill Depth Not ok Stopper Excess Movement Observed Stopper Arrangement bolt thread damaged / washout Detection Side Counter Drill Depth Not ok 100% not check at final stage Type Of Phenomena New/Repeated If Repeated No. Of Occurrence   1 Tool Side bore counter depth o/s Job Loading Job Handling Unskilled manpower Inward Material condition 1-Receiving Mtl. 2- Buffing 3- Drilling 4- Rough Boring 5- Back side chmf 6- 5.1 Drilling 7- Boss Drilling 8 – M6 Boss Facing 9- Lug Milling 10- Slitting & Facing 11–Counter Drilling 12- Deburing Chmf . 13 – Pressing 14- Welding 15- P. Coating 16- Tapping 17- Fine Boring 18- F. Inspection Spindle run out Drill Length U/S Job clamping Fixture cullet condition 26 Stopper setting

27. Photo Before After Stopper thread damage After Provided new stopper at counter drill m/c Provided New gauge for checking Start Inspection at Final stage with bolt .

28. M-25 THREADING NOT OK 7

29. DEFECT PHENOMENA DETAILS Phenomenon : M25 Threading Not Ok ・ Supplier: . Marathwada Auto comp pvt ltd ・ Model: Under bkt Assly B104D ● Parts Stock check results   NG Parts OK Parts   Area Total Stock Checked NG Status ETPL end 300 299 1 Completed Warehouse Completed Transit   Completed MACPL end finish 350 350 completed WIP         ・ Parts No.: F20502107B ・ Parts name: UND BKT B104D ・ Date of Occurrence: 27. 1 1 . 2021 Powder on threading OK Part Spec - No powder on Threading Observed- Powder observed on Threading

30. ACTION PLAN FOR Detection Side Countermeasure Occurrence side countermeasure 100% visual Inspection at powder coating stage & Final stage. Remove all damage masking to powder coating area and added new masking. Training provided to All new Operator Parameter Specification Act. Observation Jud. M25*1 Threading No Powder on M25 Thread Powder Observed on Thread Not Ok C’ Measure:- Problem Phenomenon : Total Qty. Ok Qty. NG Qty. 300 299 1 Part Name: UBA J D Process Flow: Cause Verification & Fact Analysis: Powder on M25 thread Man M/c Material Method Sr. No Possible Causes Verification Result 1 Unskilled Manpower skilled Manpower used   √ 2 Job Loading Job Loading Found OK √ 3 Job Handling Job Handling Found Not Ok √ 4 Job clamping Job Clamping found ok √ 5 Oven temp. Oven temp found ok   √ 6 Masking Cleaning Masking cleaning found not ok X 7 Masking condition Masking condition found not ok X 8 Masking crack Crack Masking Observed X 9 Inward material condition Inward material condition found ok   √ Problem Analysis:   Why-1 Why-2 Why-3 Occurrence Side Powder Observed on Thread Powder coating dust observed inside Top masking powder coating masking not clean before loading. Detection Side Powder Observed on Thread Not checked by final Inspection stage . Skip from Final inspector Type Of Phenomena New/Repeated If Repeated No. Of Occurrence   1 Tool Powder on Threading Job Loading Job Handling Unskilled manpower Inward Material condition 1-Receiving Mtl. 2- Buffing 3- Drilling 4- Rough Boring 5- Back side chmf 6- 5.1 Drilling 7- Boss Drilling 8 – M6 Boss Facing 9- Lug Milling 10- Slitting & Facing 11–Counter Drilling 12- Deburing Chmf . 13 – Pressing 14- Welding 15- P. Coating 16- Tapping 17- Fine Boring 18- F. Inspection Masking ware out Job clamping Masking crack 30   Why-1 Why-2 Why-3 Occurrence Side Powder Observed on Thread Crack masking observed on M25 Threading. Crack/ tear masking not removed. Detection Side Powder Observed on Thread Not checked by final Inspection stage . Skip from Final inspector Oven temp Masking Cleaning

31. Photo Before all crack/ tear out masking observed . After Provided air for masking cleaning Training provided to all operator New Masking Provided . 100% Inspection at final stage

32. 8 CENTRE BOSS THICKNES 23.5MM & 2 MM DISTANCE NOT OK

33. DEFECT PHENOMENA DETAILS 33 ● Phenomenon : Centre Boss Thk 23 mm & 2 mm distance not ok ・ Supplier: . Marathwada Auto comp pvt ltd ・ Model: K-2015 ● Parts Stock check results   NG Parts OK Parts   Area Total Stock Checked NG Status ETPL end 50 50 12 completed Warehouse Completed Transit   Completed MACPL end finish 450 450 45 completed WIP         ・ Parts No.: F20507307B ・ Parts name: Under Bkt assly k-2015 ・ Date of Occurrence: 19.7. 2021 Not Ok OK Part Spec - Centre boss Thk 23mm & 2 mm Observed- 22.1 mm & 1.1 mm

34. ACTION PLAN FOR 2 mm distance not ok Detection Side Countermeasure Occurrence side countermeasure Provided centre width gauge for 100% inspection. Check 1 st Five piece approval every setting. After setting program will be lock & remove the key out side . Parameter Specification Act. Observation Jud. Centre Boss Width not ok & Relation centre to side boss 23.0 ± 0.2 & 2.0 ±0.2 22.1 , 22 . & 1.1 mm Not Ok C’ Measure:- Problem Phenomenon : Total Qty. Ok Qty. NG Qty. 50 48 12 Part Name: UBA K -2015 Process Flow: Cause Verification & Fact Analysis: center boss width U/s Man M/c Material Method Sr. No Factor Possible Causes Verification Result 1 Man Unskilled operator Skill matrix verified & found ok for all pressing & welding stage operator   √ 2 Less awareness to operator Training records verified & found ok √ 3 Set up verification wrong Set up verification found ok √ 4 Method Job resting not ok Job resting block found ok √ 5 Job clamping Method not ok Job clamping found ok.   √ 6 Machine Offset on VMC program Wrong offset provided after insert change X 7 Excess stroke provided on Z height Excess z- Height provided on program X 8 Power failure Machine will resume working from previous stop point- auto control √ 9 Material Forging centre boss width u/s Forging centre width found ok   √ 10 Forging centre boss width o/s Forging centre boss width found ok   √ 11 Forging mismatch Forging mismatch found 0.3 mm.   √ Problem Analysis:   Why-1 Why-2 Why-3 Why4 Occurrence Side Centre Boss width not ok Excess machining cut on centre boss On VMC Program Z- offset found excess. Program not locked Detection Side Centre Boss width not ok Skipped from VMC operator Sample Base Inspection Type Of Phenomena New/Repeated If Repeated No. Of Occurrence   2 Centre Boss width not ok Job resting not ok Unskilled manpower Forging centre boss width u/s 1-Receiving Mtl. 2- Buffing 3- Drilling 4- Rough Boring 5- Back side chmf 6- 5.1 Drilling 7- Boss Drilling 8 – M6 Boss Facing 9- Lug Milling 10- Slitting & Facing 11–Counter Drilling 12- Deburing Chmf . 13 – Pressing 14- Welding 15- P. Coating 16- Tapping 17- Fine Boring 18- F. Inspection Wrong offset provided on vmc program Job clamping not ok Set up verification wrong Excess stroke provided on Z height Insert break Power Failure Forging mismatch Forging centre boss width o/s

35. Photo Provided Snap gauge & 100% Inspection after machining & check 2 mm distance . Display work Instruction shop floor Excess Z- Height observed on VMC program & Program not locked Correct the Z- height in VMC program & remove key after locking the program . Before After

36. 9 PRESSING HEIGHT NOT OK

37. DEFECT PHENOMENA DETAILS 37 ● Phenomenon : Pressing Height not ok ・ Supplier: . Marathwada Auto comp pvt ltd ・ Model: K-2015 ● Parts Stock check results   NG Parts OK Parts   Area Total Stock Checked NG Status ETPL end 80 80 5 completed Warehouse Completed Transit   Completed MACPL end finish 50 50 2 completed WIP         ・ Parts No.: F20507307B ・ Parts name: Under Bkt assly k-2015 ・ Date of Occurrence: 16.6. 2021 Pressing Height Not ok OK Part Spec - Height - 220 - 0.5 mm Observed- 219.06.

38. ACTION PLAN FOR Pressing height not ok Detection Side Countermeasure Occurrence side countermeasure Special gauge prepared to check pressing height 100% at final inspection. Awareness training given to final inspection operator through OPL Limit switch added in ram to have auto return stroke of ram by sensing shaft position after complete pressing. Manual error possibility eliminated completely. Parameter Specification Act. Observation Jud. Shaft pressing Height 220 -0.5 219.06 Not Ok C’ Measure:- Problem Phenomenon : Total Qty. Ok Qty. NG Qty. 80 75 05 Part Name: UBA K -2015 Process Flow: Cause Verification & Fact Analysis: Pressing Height Not ok Man M/c Material Method Sr. No Factor Possible Causes Verification Result 1 Man Unskilled operator Skill matrix verified & found ok for all pressing & welding stage operator   √ 2 Less awareness to operator Training records verified & found ok √ 3 Set up verification wrong As NG qty observed in single digit, we can conclude that there is no possibility of wrong set up approval. √ 4 Method Fixture block setting not ok Bolt setting to control the pressing height √ 5 Pressing setting not ok Manual adjustment of sensor to control stroke length resulting in Variation of pressing height during set up.   √ 6 Machine Incomplete stroke of Hy. ram Sensor available to control stroke length of ram √ 7 Hydraulic pressure not ok Pressure gauge available with shut off valve √ Power failure Machine will resume working from previous stop point- auto control √ 8 9 Malfunction of proxy sensor/ wrong setting of proxy sensor Sensor setting in manual so there is possibility of manual error X 10 Material Shaft length undersized In failed part shaft length found Ok.   √ 11 Shaft OD Oversized In failed part shaft OD found Ok.   √ Under Bracket ID undersized In failed part under bracket ID found Ok.   √ 12 Problem Analysis:   Why-1 Why-2 Why-3 Why4 Occurrence Side Steering shaft pressing height not ok Excess Pressing of shaft in forged bracket Pressing machine sensor malfunctioning/ wrong setting of sensor during setting Manual adjustment of proxy sensor during pressing setting Detection Side Steering shaft pressing height not ok Skipped from final inspection stage Sampling based inspection Type Of Phenomena New/Repeated If Repeated No. Of Occurrence   2 Pressing Height Not ok Pressing Method Not ok Unskilled manpower Shaft length undersize 1-Receiving Mtl. 2- Buffing 3- Drilling 4- Rough Boring 5- Back side chmf 6- 5.1 Drilling 7- Boss Drilling 8 – M6 Boss Facing 9- Lug Milling 10- Slitting & Facing 11–Counter Drilling 12- Deburing Chmf . 13 – Pressing 14- Welding 15- P. Coating 16- Tapping 17- Fine Boring 18- F. Inspection Malfunctioning of proxy sensor- wrong sensor setting Fixture Block setting Not ok Set up verification wrong Incomplete stroke of hydraulic ram Hydraulic pressure not OK Power Failure Under bracket ID undersize Sheering Shaft OD Oversize

39. Photo 39 BEFORE AFTER Limit switch added in ram to have auto control , on Confirmation of complete pressing of shaft. Eliminated manual intervention. Also detect short length shaft. Set up procedure was based on proxy sensor positioning (Manual) causing length variation during set up HOME POSITION STROKE ADJUSTMENT SENSOR Sensor position adjusted to control ram stroke during set up resulting in possibility of NG part generation due to manual adjustment HOME POSITION Limit switch Inside pressing ram OK Process Process IF NG Manual Intervention for inspection eliminated (Setup rejection eliminated) Bracket Shaft Pressing Ram Limit switch Bracket Shaft Pressing Ram Limit switch Limit switch get operates after complete pressing & ok signal given to machine Malfunctioning of stroke adjustment sensor Fix stopper provided instead of bolt

40. Photo Provided New Height gauge for pressing height checking Check pressing height on height gauge OPL display on shop floor & final Inspection Table

41. DEFECT PHENOMENA DETAILS 41 ● Phenomenon : Shaft OD Over size ・ Supplier: . Marathwada Auto comp pvt ltd ・ Model: K-19 ● Parts Stock check results   NG Parts OK Parts   Area Total Stock Checked NG Status ETPL end 300 300 completed Warehouse Completed Transit   Completed MACPL end finish 450 450 completed WIP         ・ Parts No.: F20510907 ・ Parts name: Under Bkt assly k-19 ・ Date of Occurrence: 11.11.2021 Pressing Height Not ok OK Part Spec - Height - 23.5 -0.05/-0.15 Observed- 24.082.

42. 4 Shaft OD over size

43. ACTION PLAN FOR Shaf t od over size Detection Side Countermeasure Occurrence side countermeasure 100 % job check by ring gauge before dispatch. Awareness training given to final inspection operator through OPL Material handling improvement single flow. Separate bin provide for tube transaction from supplier. Parameter Specification Act. Observation Jud. Shaft od over size 23.5 -0.05/-0.15 24.080 Not Ok C’ Measure:- Problem Phenomenon : Total Qty. Ok Qty. NG Qty. 300 300 Part Name: UBA K -19 Process Flow: Cause Verification & Fact Analysis: Man M/c Material Method Sr. No Factor Possible Causes Verification Result 1 Man Unskilled operator Skill matrix verified & found ok for all pressing & welding stage operator   √ 2 Less awareness to operator Training records verified & found ok √ 3 Set up verification wrong As NG qty observed in single digit, we can conclude that there is no possibility of wrong set up approval. √ 4 Method Fixture block setting not ok Bolt setting to control the pressing height √ 5 Pressing setting not ok Manual adjustment of sensor to control stroke length resulting in Variation of pressing height during set up.   √ 6 Machine Incomplete stroke of Hy. ram Sensor available to control stroke length of ram √ 7 Hydraulic pressure not ok Pressure gauge available with shut off valve √ Power failure Machine will resume working from previous stop point- auto control √ 8 9 Malfunction of proxy sensor/ wrong setting of proxy sensor Sensor setting in manual so there is possibility of manual error √ 10 Material Shaft length undersized In failed part shaft length found Ok.   √ 11 Shaft OD Oversized In failed part shaft OD found Ok.   √ Under Bracket ID undersized In failed part under bracket ID found Ok.   √ 12 Problem Analysis:   Why-1 Why-2 Why-3 Why4 Occurrence Side Steering shaft OD 23.5mm oversized Go Gauge not qualify Damage mark observed on tube top surface Detection Side Steering shaft OD 23.5mm oversized Skip from final inspection Type Of Phenomena New/Repeated If Repeated No. Of Occurrence   Shaft od over size Material handeling Method Not ok Unskilled manpower 1-Receiving Mtl. 2- Buffing 3- Drilling 4- Rough Boring 5- Back side chmf 6- 5.1 Drilling 7- Boss Drilling 8 – M6 Boss Facing 9- Lug Milling 10- Slitting & Facing 11–Counter Drilling 12- Deburing Chmf . 13 – Pressing 14- Welding 15- P. Coating 16- Tapping 17- Fine Boring 18- F. Inspection Under size over size job manufacture on machine Set up verification wrong Iinsert point wear out Offset setting , insert change Power Failure Sheering Shaft OD Oversize

44. ONE POINT LESSION 44 BEFORE AFTER 100% Inspection at final stage 100% Tube Inspection at Inward & Final stage. ( Provided dot mark for Ok shaft at inward stage)

45. 45 BEFORE AFTER Only top surface diameter observed O/S . At Middle portion dia. found Ok. Use trolley for material hadling and Raw tube for bins are available

46. THANK YOU