QA-PI Division

Process Audit Report

Purpose of visit : Process Audit of YAD Parts

Vendor Name : M/s Agro Engineering Works Faridabad
Parts Supplies to MSIL : Bkt T/M Cont Cable, Bkt Cluth cable,
Model : YAD
Process Audit Date : 29th Jan 2015
Part name for Process Audited- Bkt T/M Cont Cable ( 28390- 65M10 )
Vendor Person(UDI) MSIL Person
1) Devender Malik 1) Damodar Dhyani QA PI-E1
2) Mr. Greesh singh 2) Anant Saran Pandey EN5D2

3) Mr. Dubey
Key Observations / Improvement Areas of this Audit
S No Key Observation / Major Improvement Area Required Action Target date Action taken Sketch / Photo Status /Date
as proof

1 Raw Material :
1.1 Raw materail grade required as per drawing is Third party material report for each lot M/S Agro Engg will
inform target date
JSH270CN-P, and M/S Agro is using HRC-D should be available along with for all observations
pickled comparison sheet. by 05th Feb 2015

1.2 Raw material supplier is Tata steel and is single
source. It is not mentioned in Control plan.
The raw material source should be
explicitly mentioned in the control plan
and if in future there is any change in the
procurement source, the same should be
informed to MSIL.

2 Control plan
2.1 Control plan is not up to the mark. Some All Drawing parameters should be M/S Agro Engg will
inform Modified
dimensions & processes are missing. Example : mentioned in Control plan and critical PPAP document
welding weight location mismatch ,some dim to dim should be in MIS-P and should date by 05 Feb
2015
be checked at start ,mid and end as per PCS but perfectly match with running process and
being checked only at start. Window Angle 30 internal inspection check sheet.
Deg and 41 Deg missing. Deburring operation
also missing.

2.2 During Draw of Bkt, thinning at corner (A-F) The mentioned parameters should be
check point available in control plan but A -F clealy identified and mentioned in
location not clearly identified Control plan and check sheet

2.3 Spot weld parametres, SQ time and Weld time Parameters to be optimized for different
were not matching with control plan. Reason for parts so as to avoid wrong setting and
this as given by vendor is that the settings had spot failure.
been done for some other model part.

2.4 At spot weld machine electrod dia checked with Spot weld electrode dia and shape
cabon impression but there is no fixed grinding to be fixed and taper gauge for
frequency for electro dia checking and checking electrode shape and size to be
resharpning procured.

3 Inspection Observation :
Key Observations / Improvement Areas of this Audit
S No Key Observation / Major Improvement Area Required Action Target date Action taken Sketch / Photo Status /Date
as proof

3.1 Thinning measured by point micrometer , this is Pistol type dial gauge for checking
very time taking and there is no repeatability in thinning should be used.
the result.

3.2 During punching operation Hole dia and CD CD checking gauge and plug gauge to be
checked by Panel checker made.

3.3 Flatness at Window side Dia 38 and hole dia All Drg parametrs should be maintained
side , observed up to 0.50 against spec of 0.2 within tolerance.
max. Also the gauge is showing the part ok. The gauge should be able to clearly
differentiate OK and NG parts.

3.4 During setting, gauge and instrument not One set of gauge and instrument reqiured
available at location; parts are being checked in at location and observation check sheet
inspection room , which is time consuming should also be availbale at work station

3.5 Chamfer angle 30 Deg and 41 Deg Hole side As discussed in Spec meeting profile
chamfer C 0.3-0.5 not checked by vendor projector required for Angle and dim
checking at small length area.

3.6 Dia 18.8 Hole shape Chamfer opposite shearing It is required to check and measured
C0.3-0.5 is not up to mark; is being checked length and Angle of chamfer .
visually & there is no provision to check Chamfer
angle and length.

3.7 Sheet thickness, Dim 28.2 +0.3, Dia 31.65 + 0.2, Except flatness other parameters found
Flatness 0.2 max, Parallelism, Mtg Dim Ok. However Angle parameters are not
,Thinning,Weight location, Nugget dia and checked by vendor
formation, Weld penetration leg , throat,
parameters checked during process audit.

4 Fixture and Gauges :

4.1 Welding fixture hole locator pin dia loose in Bkt Proper drawingof welding fixture should
hole , and height was also less. There is no be available and locator pin dia should be
drawing and spec of fixture and its child parts. calibrated.

4.2 In Weight welding fixture weight held by toggle Required magnetic side block to avoid
clamp but there are chances of shift in the disturbance in weight position
position.

4.3 During both Bkt welding, window area is open. As discussed in Spec meeting casing cap
There are chances for weld spatter at cable covering required at window area to
fitment area. avoide spatter.

4.4 R/gauge had no provision for checking child part R/Gauge to be modified to check whole
Breather hole position part in one time

4.5 Gauge used for process inspection with out All Guages , instrument ang jig fixture
control no. should have control no. and calibtration
schedule.

4.6 Main Bkt is Common for all Diesel model as well Atleast 2 sets of tools are required.
as YAD, YV4D,YL1D,YY4D. But only one set of
punch and tool available at vendor
Key Observations / Improvement Areas of this Audit
S No Key Observation / Major Improvement Area Required Action Target date Action taken Sketch / Photo Status /Date
as proof

4.7 Child Part Bkt Breather is common for YAD, YV4D
and YY4D.
Process was not in running condition. Already
available parts found NG : Burr at window side,
Uneven wall thickness, Inclined window axis,
Uneven Corner Radius and profile.
.. Date of Die loading for process audit to
be informed.
.. Correct the existing tool or install new
tool to control all parameters.

4.8 Same gauges and instrument used at process Separate sets required; minimum 2 sets
and final inspection. of gauge and fixture required.

5 Other Observation :

5.1 Inhouse movement of parts for plating is in bad Inhouse and out side movement should
condition. The bins were over loaded. be standardized.

5.2 Bins for material movement not up to mark Bins cleaning should be strengthened,
need a schedue for proper bin cleaning.

5.3 Skill matrix not available at work station even Operator skill matrix should be displayed
critical work station as Chamfer at work area.
punching,welding and spot weld station

5.4 Spec meeting points closure not availble Spec meeting closure report to be
submitted

5.5 Part Drawing needs some rectification regarding Clarification to be done along with EN5D2
Both faces parallism and child Bkt Breather
shape.
5.6 MIS-P Dimension and other critical parameters Critical dimsoins should be measured and
checking before dispatch checked before packing and dispatching..

5.7 There are chances of mix up in supply. Wrong M/S Agro will make a Matrix for all
part, wrong child part and other model weight Bracket Cont Cable to avoid mixing of
may get used. wrong child part weight. Also inform
control in process to avoid mixing.

Past Problem Countermeasures Verification

S No QPCR/Defect/Last Audit Observation Counter
measur
Status during the audit Remarks
e Given

Dia 28.2 over size deformed in fixture due to ………. C/measure is efective and since Part shape is
back force verified different, there is no such possibility.

Key Improvements after last Audit (If any)

Person In-charge
Damodar Dhyani