8 D PROBLEM RESOLUTION REPORT Doc. No.

- SECPL/CAPA/01
Date - 01.08.2021 Rev. No. - 00

Part Name Transformer Tank Project Madhepura

Drg Ref 2XCH200000-CDP (Transformer Tank No. 225) Supplier Part No. 2XCH200000-CDP

Drg.Modification status B
Date 18.12.2023 Feedback from Vijay Gupta
Location Incoming Assembly Testing Final Customer Site

PROBLEM STATEMENT

Continuous weld cracks observed in tank arm Sr. No. 225 SE.(J-32)

D1 TEAM
MEMBERS NAME ROLE
Anand K Sondur Welding Head
Saad Patel DWC
Chandan Verma Plant Head
Nitin Rana Quality Heat

D2 PROBLEM DESCRIPTION
Who is affecting from the failure ? End user and Customer is affecting from the failure
What is failure ? Continuous weld cracks observed in tank arm sr. no. 225 SE.(J-32)
Where failure occurred? Failure occurred at customer site (Hitachi savli)
When problem was happen ? During tank loading or unloading observed at Hitachi savli site on dtd. 12.12.2023
Why problem occur ? Lack of fusion.
How problem/failure detected ? During the routine loading or unloading of tank.
How Many times failure occurred ? First time observed.

D3 CONTAINMENT ACTION
Location Quantity Status
HEIL 1 The crack was removed and re-welding was done at Hitachi,Savli.
(weld repair procedure no.-QSP-20-WI-10 , Rev. no. 00 dtd.01/06/2017)
Same Joint & other joints (Tank Sr. No. 235 to 244) has been checked by Ultrasonic Testing & Magnetic particle testing and
SANTO 2 found satisfactory.

D4 ROOT CAUSE ANALYSIS - WHY ~ WHY .. ANALYSIS (Attach Ishikawa diagram-Cause & Effect)
Ishikawa diagram Man
Machine After root run, hot pass
Weld sequence not followed. Edge preparation not run & caping run

covered in single run.

Method proper.
Daily welding
low ampere and
voltage used during audit was

welding. skipped.
Improper selection of filler
material.
Mother nature Material

Continuous weld cracks observed in tank arm sr.

no. 225 SE.(J-32)

WPS not followed Lack of fusion

 Doc. No. - SECPL/CAPA/01
Date - 01.08.2021 Rev. No. - 00

Madhepura
2XCH200000-CDP

B
Vijay Gupta

ROLE

J-32)

e on dtd. 12.12.2023

Assigned to
13.12.2023

26.12.2023

Continuous weld cracks observed in tank arm sr.

no. 225 SE.(J-32)
1-WHY statement Continuous weld cracks observed in tank arm sr. no. 225 SE(J-32).

2- WHY Lack of fusion.

3- WHY During welding hot pass run & caping run carried out in single run instead of 2 separate run.

4- WHY Lack of awareness of WPS reading.

5- WHY Proper training not provided.

Root cause During welding hot pass run & caping run carried out in single run instead of 2 separate run.

D5 CORRECTIVE ACTIONS / LONG TERM ACTION (Attach Photographs of actions taken)

1. Training given to welder and skill matrix updated

te run.

te run.

Assigned to: Anand K Sondur

Date: 30.12.2023
 Assigned to: Anand K Sondur
2. Control Plan updated.
Date: 30.12.2023

Assigned to: Anand K Sondur

3. PFMEA updated.
Date: 30.12.2023

D6 MONITORING EFFECTIVENESS OF CORRECTIVE ACTIONS (REVIEW)

No Corrective Actions Taken Target Date Actual Date Result of Action Date of
Review
Training given to welder and skill matrix updated. 18.12.2023 18.12.2023 Found OK. 28.12.2023

2 Control Plan updated. 28.12.2023 28.12.2023 Found OK. 28.12.2023

3 PFMEA updated. 28.12.2023 28.12.2023 Found OK. 28.12.2023

D7 PREVENTION
1. Number of layers(runs) added in weld plan. Assigned to: Anand K Sondur
Date: 28.12.2023
r

Status

Closed

Closed

Closed

r
2. Daily welding audit will be conducted two times per day. Assigned to: Anand K Sondur
Date: 29.12.2023

3. Before welding,during welding & after welding checksheet is implemented & will be checked for all tank. Assigned to: Anand K Sondur
Date: 30.12.2023

7B REVIEW - DOCUMENTS / SYSTEMS (Attach copies of all revised documents)

No QMS Document √ if Yes Responsible Planned Date Actual Date

1 Control Plan √ Nitin Rana,Saad Patel 28.12.2023 28.12.2023

2 Process sheet √ Saad Patel 28.12.2023 28.12.2023
3 Drawing / Process Flow Diagram
4 PFMEA / DFMEA / PPAP √ Nitin Rana,Saad Patel 28.12.2023 28.12.2023
5 Process Map
6 Acceptance Standard
7 PM Checklist
8 Work Instruction/Calibration Plan
r

Status

Closed
Monitoring

Close
 8 PROBLEM CLOSURE & SIGN-OFF
PROBLEM PROGRESS SUMMARY CLOSURE SIGN-OFF
No Phase Start Date Completion Team Member Area
1 Problem Definition 12.12.2023 - Anand Kumar Sondur Welding Head
2 Containment Action 13.12.2023 26.12.2023 Chandan Verma Plant head
3 Root Cause analysis 13.12.2023 30.12.2023 Saad Patel DWC
4 Corrective Action 18.12.2023 28.12.2023 Nitin Rana Quality Head
5 Solution Confirmation 31.12.2023 31.12.2023
6 Closure 31.12.2023 31.12.2023

Total Time required for rejected product analysis in days = 19 Days

(Determination of root cause, corrective action & monitoring effectiveness of implementation)

MANAGEMENT VERIFICATION & CLOSURE

Sign

Date 24.12.2023 24.12.2023 24.12.2023 24.12.2023

Name Mr.Anand kumar Sondor Mr.Chandan Verma Mr. Saad Patel Mr. Nitin Rana

Department Head Welding Plant Head DWC Head Quality

SIGN-OFF
Sign-off

19 Days