Scribd Logo
Upload

Welcome to Scribd!

  • 55 views

    CMR For 2gs Am Crack

    Uploaded by

    Kumaravel
    1) A crack was observed in a forged part after machining due to multiple handling damages creating a deep scratch that propagated during forging. 2) Analysis found the scratch was caused by handling during production and inspection missed closed damages. 3) Countermeasures included training, inspection changes, handling procedure updates like spiral rings and padding to prevent deep scratches during production and transit.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd

    CMR For 2gs Am Crack

    Uploaded by

    Kumaravel
    55 views7 pages
    1) A crack was observed in a forged part after machining due to multiple handling damages creating a deep scratch that propagated during forging. 2) Analysis found the scratch was caused by handling during production and inspection missed closed damages. 3) Countermeasures included training, inspection changes, handling procedure updates like spiral rings and padding to prevent deep scratches during production and transit.

    Original Description:

    Customer Complaint Analysis Report

    Original Title

    Cmr for 2gs Am Crack

    Copyright

    © © All Rights Reserved

    Available Formats

    PPT, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    1) A crack was observed in a forged part after machining due to multiple handling damages creating a deep scratch that propagated during forging. 2) Analysis found the scratch was caused by handling during production and inspection missed closed damages. 3) Countermeasures included training, inspection changes, handling procedure updates like spiral rings and padding to prevent deep scratches during production and transit.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    55 views7 pages

    CMR For 2gs Am Crack

    Uploaded by

    Kumaravel
    1) A crack was observed in a forged part after machining due to multiple handling damages creating a deep scratch that propagated during forging. 2) Analysis found the scratch was caused by handling during production and inspection missed closed damages. 3) Countermeasures included training, inspection changes, handling procedure updates like spiral rings and padding to prevent deep scratches during production and transit.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 7

    COUNTERMEASURE SHEET REFERENCE NO.

    :)
    DATE :
    CE:01:F:02
    APPROVED CHECKED ISSUED
    PART NAME : 2GS– Axle Main VENDOR :3856 Shyam
    PART NO:2GS–E7411 –W0 MODEL : Matsuura Kumar
    Kumar
    (Koyama)

    PROBLEM ANALYSIS COUNTERMEASURE


    C’measure of “Why Make”
    Occurrence timing Analysis of “Why Make” 1) Following actions are implemented and
    i) While producing forged part no in placed to avoid deep handling
    07.06.16,at IYM FBD ,1 no's NG
    damages in sun flag.
    defect found, after 3.5 mm
    Phenomena problem  Spring ring on outer diameter of
    machining at IYM FBD internal individual bar.
    Crack observed at forging parts after scratch exposed.  Rubber pads use on every station of
    machining. ii) Multiple Handling of the bars processing.
    generated a deep handling damage  Wooden plank use to avoid contact of
    at localized spot at sun flag end bundle to bundle.
    which got propagated during  Packing table covered with hessian cloth
    during packing of material.
    forging operation.
     Spiral ring is use on bars immediately
    after MPI instead of during packing of the
    material to avoid handling mark.

    Standard
    Analysis of “Why Send” C’measure of “Why Send”
    Raw material Surface defect should be
    In Koyama end In 2GS AM part 100% 1) Training and alert given to
    ≤0.15mm by ECT / ≤0.1mm by(Manual) visual inspection only carried out in operators to reject parts which have
    Drawing final inspection process, whereas closed as well as hairline scratches
    Forge finishing surface must be free closed damages are unable to detect by during final inspection.
    from harmful rust, dent, dirt etc., visually.
    2)Quality Alert displayed at
    Confirmation of C/M production & Quality area.
    1.Physical part(N100min)- OK/NG
    3) One Point lesson teached to all
    2.Standard(QCPC,W.I.,SOP)-OK NG
    operators & Inspectors.
    3.Education(Record)-OK/NG
    4.Operator Skill check-OK/NG
    All are required evidence (Record, e.t.c)
    2GS AM Process Flow Diagram:

    Raw Material Receipt


    Press 2
    &Issue

    Sawing Bonderising 2

    Chamfering Press 3

    Weight & Visual Final Inspection


    Inspection (100 % runout & Visual)

    Bonderising 1 Supply Inspection

    Press 1 Packing

    Dispatch
    KOYAMA Precision Works INDIA Pvt Ltd
    2GS AM Process Flow Diagram – Possible Root Cause Processes:

    Raw Material Receipt


    Press 2
    &Issue

    Sawing Bonderising 2

    Chamfering Press 3

    Weight & Visual Final Inspection


    Inspection (100 % runout & Visual)

    Bonderising 1 Supply Inspection

    Press 1 Packing

    Dispatch
    KOYAMA Precision Works INDIA Pvt Ltd
    Action Taken in Sunflag:

     FOLLOWING ACTION ARE TAKEN ARE TAKEN TO AVOID DEEP HANDLING DAMAGE IN SUNFLAG END

    1 2 3

    Spiral ring provided on outer Rubber/Tefflon pads use on Wooden plank are provided
    diameter of every bar every station of processing between bundles during
    transit to avoid contact

    KOYAMA Precision Works INDIA Pvt Ltd


    Action Taken in Sunflag:

     FOLLOWING ACTION ARE TAKEN ARE TAKEN TO AVOID DEEP HANDLING DAMAGE IN SUNFLAG END

    4 5

    Packing table are covered Spiral ring is use on bars


    with hessian cloth during immediately after MPI instead of
    packing of the material. during packing of the material to
    avoid handling mark.
    Investigation Report
    from Sunflag
    KOYAMA Precision Works INDIA Pvt Ltd
    KOYOMA Precision Works INDIA Pvt Ltd
    Quality Alert Display : Alert displayed in Production, final inspection ,dispatch area for better understanding of workers.

    2GS AM CRACK
    KOYOMA Precision Works INDIA Pvt Ltd
    One Point lesson: issue was informed to all operators, PPC Persons and Final inspectors to create awareness

    2GS AM CRACK

    You might also like