Action List from Quality - Metso

# Main Problem Responsible

Insha / Deepak /
1 HKI Claims
Abhishekh

2 Shanghai Claims Saurabh / Deepak

3 Horgau claims Deepak

4 465890 Horgau disc porosity issues Deepak / Shubham

H164819 - Pressure class marking issues in 13 nos. in

5 Deepak
March 2020

6 Material Certificates auditing Gaurang

 Offering parts to Vishal

1. Documentation.
7 Deepak
2. Marking.
3. Viual Inspection.
4. Welding repair.

8 PO: 6038457, 465890 Horgau disc Akhtar / Vishal

9 M-144-En Rev. 4 discussion Shubham

10 Segment Ear Symmetry Deepak / Shubham

11 CMM Inspection in Lockdown Akash / Akhtar

12 New claiming system Insha / Gaurang

Akhtar / Rohit
13 Jane Du's email regarding LWL500 Dimensions issues
Agrawal
14 Sample Feedback - 2020 Deepak

00154 - H171653 - BODY M1YW350 4A - CH. 19BWD.

15 Through the leak on pressure test. Rejected 1 pc at Deepak / Saurabh
Neles.

Claim No: 00311 - H044654 - CST SEGMEN RB500 Deepak / Saurabh /

16
CK3MCuN - 1 No. rejected Vishal

17 410040 - L1D disc / Lower outside diameter Deepak / Abhishekh

 Supplier PTC Industries Ltd.

Agreed Date Action Status

4/30/2020 In-Process

4/17/2020.
13.05.2020 In-Process
27.05.2020

4/28/2020.
Close
5/4/2020

4/15/2020 In-Process

4/30/2020.
4/29/2020.
5/13/2020.
Close
10.07.2020
15.07.2020
23.07.2020

Not sure Open

5/4/2020 Close

5/13/2020
In-Process
10.06.2020

Not sure Close

5/15/2020
10.06.2020 Close
15.07.2020

27.05.2020
Close
10.06.2020

In-Process

27.06.2020 In-Process
 7/8/2020
In-Process
29.07.2020

05.08.2020
In-Process
13.08.2020

20.08.2020 In-Process

13.08.2020 In-Process
ndustries Ltd.

06.08.2020

Not discussed as Insha didn’t joined meeting

Not discussed as Insha didn’t joined meeting

Last 3 POs already shipped and this parts has been received on
29.07.2020.
We have already asked Horgau plant to take this parts to
machining so we can check the quality / blowholes.

8D submitted and corrective action discussed in meeting.

Now, responsibility and process set again. Pressure class

removed from pattern / die and packing personnel will be
responsible to check Pressure class according to Purchase order.

This actions is implemented to all shipments after 25.07.2020.

Planned but due to lockdown not possible before 30th of August

Parts has been shipped and it will reach to Horgau plant around
mid September.

from earlier meeting to this date, Saurabh received 2 claims.

(Shanghai).

Buyers need to send claims to supplier which are pending.

Deepak will check with Akthar and Rohit and he will send
response --> 11.08.2020
EMEN11-7415 / HKI-19-3058 - This is sample part and LPT was
missed / not done properly in PTC on serration area which leads
this gas porosity issues on raised face.

For scratches CAR is fine they will take more care during internal
transportation within company.

As discussed with Deepak, CAR submitted needs to be revised as

LPT didnt mention anywhere in root cause. And, if PTC have
photos then please submit --> 10.08.2020

As per discussion with Deepak, we came to know that PTC is

taking photographs during LPT so now Vishal will check with
Akash / Sankalp to submit photographs for LPT parts which
asked in PO or with tailcode items.

Part is Rapid Cast one. Its still not confirmed but Saurabh will
confirm it --> 10.08.2020.

8Ds --> 1 week more time needed.

Gaurang will check 4A orders from Luknow and send list to

Saurabh.

Currently after machining NO LPT done in regular orders. It will

be done whenever its asked in PO.

Saurabh will check and discuss internally.

Vishal will send photos / Heat number of this recent claim from
Powerapps 00311.

From old claim system : EMEN10-34129 - CH. 1979G. 2-4. Gas

porosity on machined shaft place. Repaired 4 pcs at
Metso.,Kindly comment on claim costs as soon as possible.

Engineering has sent an email of confirmation to Deepak that die

already modified for outer diameter.

So, dimensional report of pattern / die - (Abhishekh will check

open PO report).

Also, we want to know when die has been modified.

 22.07.2020

Mostly HKI claims received to PTC.

Claims received in excels only. New format Claims not yet

received by PTC.

Last 3 POs already shipped. Current line status is 40. (which

means in transit)

8D submitted and current discussion which Deepak is talking in

which responsibility of pressure class checking is packing
department and that is totally difference from 8D submitted.

So, kinldy update 8D --> 23.07.2020

Planned but due to lockdown not possible before 30th of July

this item already shipped. Waiting for results.

As per confirmation from Deepak, PTC will check 100%

dimensional for this critical dimensions from 22.07.2020
onwards.

As CMM reports are now Vishal getting so we are closing this

point.

3 Claims received by Insha.

Open Orders reports are awaited.

As of today total 9 nos Samples results pending for 2020 filter
with supplier. Out of that 5 nos. already asked and 4 nos.
pending to ask feedback.

2 nos. Feedback received today from Insha.

Remainning 3 nos. PTC will give feedback on : 1 week.

Gaurang will send remaining 2 nos. supporting documents on

22.07.2020

Claim has been received by PTC as confirmed by Saurabh.

Initial investigation - 1 week.

Final 8D submission - 1 week.

Pattern no : RX9425 used for three materials till date according

to Open PO sheet.

CK3, CF8M and 142324.

Rejection rate for CK3 is 45.45 %, 142324 is 12.50 % and CF8M

0%.
 08.07.2020

New claims has been received to Insha. Only 1 claim / plant

received. (3 nos in June month)

New claims has been received to Insha. Only 1 claim / plant

received. (3 nos in June month)

Last 3 POs already shipped. Current line status is 40. (which

means in transit)

8D submitted for this one.

@Vishal - Items which have BV inspection those are followed by

Route card and this is verified by Vishal but now need to check
for other lines which are not selected for BV lines.

Things to check is presusre class is mentioned in report correclty

or not at CMM and final inspection area.

final words during meeting - PRessure class is not parrt of Route

card. deepak will check intenrally and get back to it.

Planned but due to lockdown not possible before 30th of June

So, Now vishal is getting route card for BV lines so we are
closing this point.

RT completed - Film verified and found okay.

LPT - Not done yet.
Visual & Dimension - Pending. (Radius R5 & R10 not properly
found internal inspection). For this No welding will be done.

Methoding --> @Shubham will check and confirm till XYZ dates.

@vishal - Please check this part physically in next visit.

8D submitted for this one.

Internal Inspection frequency not set yet. So, randomly parts are
choosen for inspection from PO Quanitty.

10% inspection can be planned. Also, Deepak will check this ear
symmetry dimension can be put 100% for dimensioanl inspection
(partical this dimensions only).

CMM reports are receiving now.

Old CMM having issues for exporting reports. But for Bigger Zeiss
CMM Vishal is getting CMM reports.

Insha is getting claims 1 / plant till date received.

8D received but we are asking to take strong actions on

controling quality point.

Rohit will send email for next meeting speically for this.
HKI-19-4651, HKI-19-4650, HKI-19-4648, HKI-19-4323, HKI-
19-4322, HKI-19-4063, HKI-19-3868, HKI-19-4039, HKI-17-
1551

Above Items are having disposition of "fix process and proceed"

and "fix process and resubmit new sample" one which needs to
be addressed by PTC.

Till today No actions recieved.

 24.06.2020

due to system changes PTC are not getting claims.

Buyer will send information regarding claims.

Deepak didn’t join meeting so no updates

Deepak didn’t join meeting so no updates

Planned but due to lockdown not possible before 30th of June

Internal inspection reports shared.

- route card was not there for last inspection what Vishal did on
22.06.2020

Pouring sheet - Email & Pouring videos - Whatsapp received from

Akthar.

- Current status is : Parts are under Fetteling,

@Vishal - Need to take photos for evidences at all stages. NDTs,

HT, etc. for references.

From long time we are asking basic information about how PTC is
checking dimensions but no answers received so far.

We urge Customer support team also to look in to this.

Vishal - Please start to ask CMM report to be converted in Pdf

from computer and than it will be send as email.

Insha's email request has been forwarded but email ID will be

entered in Account in Powerapps later. So, once it was fixed we
will ask again.

Rohit asked to give 1 day time so on 24.06.2020. And, final

response PTC will share on 27.06.2020.

OOT dimensions are checked in PTC by CMM so main reason to

check this case is why so much differeces found in plant and PTC
results
 10.06.2020

Abhishekh needs to give list to PTC for which CAPA we need for
HKI, SHP and HRG claims. -->

Abhishekh needs to give list to PTC for which CAPA we need for
HKI, SHP and HRG claims. -->

Abhishekh needs to give list to PTC for which CAPA we need for
HKI, SHP and HRG claims. -->

3 Last POs items already disaptched on basis of documentations

reiveiw.

Process Improvement:
all documents needed but due to Non disclouser thing we didn’t
have any data from PTC.

Waiting for Anthony's reply. Engineering is headed by Jim so

keep him also in loop. --> Gaurang will add Jim today in email.
PTC removed pressure class from die.

Machining department working with dispatch plan so they will do

machining acording to pressure class.

During CMM inspection of flange there will be no any pressure

class punched on part. --> Here, according to drawing for
particular part inspector do inspection of flanges.

Later, this part will come to final inspection with route card at
this moment this pressure class punches. CMM QC person inform
you what is pressure class through route card.

Before BV / Vishal inspection there will be all marking available.

This process is started already. Pictures needed from deepak.

Planned but due to lockdown not possible before 30th of June

Not discussed

items are poured.

Documents pending:

- Pouring sheet.
- Pouring Video.

Training is completed in last week.

Actions: HT now done with runners and risers.

Internal balloon drawing and checking process of this inside

dimensions. --> Depeak will shared it today.

Rohit has shared email that after 3rd June all parts which we
have BV inspection for those parts CMM reports will be shared.

Vishal didn’t get CMM reports.

Akhtar will discuss with Akash and come up today evening.

Gaurang will send email to Markus today for Insha's request.

Till date PTC didn’t get new claims through emails.

 27.05.2020

New 9 nos. CAPA received by Insha which she will forward to us today with excel.

Abhishekh will give final list for which CAPA we need for All HKI, HRG and SHP plant.

Shanghai updated list already shared to Insha by Abhishekh.

Shanghai claims CAPA 6 nos. remaining. (According to Deepak only 1 was pending and it was submitted). -

Pending CAPAs we have received.

Parts Status:
Parts offered for Inspection with documents.

Process Improvement:
Method Changed: Non disclouser as per PTC Engineering.
Gating: Non disclouser as per PTC Engineering.
Pouring Sheet: recevied on 14.05.2020 --> Abhishekh will check pouring sheet.
Simulation: Non disclouser as per PTC Engineering.

Not received anything

Planned but due to lockdown not possible before 30th of June

Not discussed

Not discussed

Traininng planned on 28.05.2020

Pending to submit

Current issues:
1. CMM requirement is unclear for BVQI / regular parts.
2. All dimensions not checked by CMM. (control by process)
3. Rework - Inprocess.
4. Manual report + CMM report.
Discussion:
1. PTC check few parts (mainly first piece in all machining processes) in CMM. Later, remaining parts will be
parts and quantity. Data will be there in backup. --> Actions: Rohit Agrawal will check the pars which are pa
which are open and come back to us till 28.05.2020.
2. Dimensions which are checked by CMM those must have values in observed column. Seating area dimens
waived off for regualar parts / items and Neles can ask to check seating area dimensions if requried.
Insha need her email ID in "To" so that claim will not miss.
3. CMM inspection required only for dimesions which have closer toleracnes + GD & T + Not possible by man
Solution and agreements:

1. BVQI parts which are pending for dispatches and parts which are not packed till 27.05.2020. This parts C
can be submitted.
2. Dimensions which are checked by CMM those must have values in observed column.
3. If rework is there in final inspection - PTC can share reports whic hahve OOT observed value and later aft
completion PTC can comment on report and mentioned final observed value.
4. As agreed Manual report PTC will share as it is which they are following with CMM reports.
 13.05.2020

Total 5 nos. New CAPA submitted.

5 Nos. CAPA Pending. (heat number wrong, etc) this is pending as other
department involved. --> Approx by Monday (18.05.2020) they will try to
complete.

Today Saurabh have plant to submit CAPA except Arrow direction wrong
claim.

-Part
Insha needs claim numer against NC number. --> Gaurang. (18.05.2020)
Status:
1500120 - 7 pcs (Under fettling, RT OK), UT completed and found okay. -
Ready for Vihal's inspection. (No any repair welding in this 7 Pcs.)
9001438 - 1 pcs under fettling, RT ok. UT also completed and found okay.
9001333 - 5 Nos.by
2 CAPA received Under RT.on 13.05.2020
Deepak

All above items are hipped.

Reparing:

Till date no Repair welding happened. Confirmed by Akhtar.

Process improvement: (Deepak) 4th May 2020

RT & UT 100% implemented.

Method Changed: Non disclouser as per PTC Engineering.

Gating: Non disclouser as per PTC Engineering.
Pouring Sheet: Deepak will discuss this and come back (13.05.2020).
Simulation:
hipping added or not that is open question.: Hipping is added for above
POs.

Deepak will update by today evening.

Planned but due to lockdown not possible before 4th of May.

Route card is not yet implemented as during Vishal's inepction it was not
shown.

Quality Plan / Action plan

Replicast pattern with Methoding inspection.

Mould making witnessing.
Pouring witnessing.
Inspection after Pouring and before Knockout.
After Knockout inspection (before UT , RT).
Hipping process need to be informed to vishal before starting.
Witnessing UT and RT (film verification).
Witnessing Repair welding if applicable after NDTs.
Final inspection by Vishal.

Training will be planned after this Lockdown.

Internal inspection ballooning drawing.

 29.04.2020

Total 11 Nos. CAPA submitted.

10 Nos. pending to submit CAPA. And Deepak will submit 3~4 nos. CAPA
within 2 days.

For remaining CAPA Deepak will update me tomorrow.

Claim list has been forwarded to PTC but No action yet done. Email was
skipped by PTC.

Discs one Claims : CAPA can be submitted within 1 week (6th May
2020).

Part Status:
Others : Deepak will check and confirm.
1500120 - 7 pcs (Under fettling, RT OK), UT completed and found okay.
9001438 - 1 pcs under fettling, RT ok. UT also completed and found
okay.
Deepak will submit 8D on 4th May 2020.
9001333 - 5 Nos. Under RT.

All above items are hipped.

Reparing:

Till date no Repair welding happened. Confirmed by Akhtar.

Process improvement: (Deepak) 4th May 2020

RT & UT 100% implemented.

Method Changed:
Gating:
Pouring Sheet:
Simulation:
hipping added or not that is open question.:

Deepak will reply today for this.

Planned but due to lockdown not possible before 4th of May.

effectiveness will be checked after lockdown.
 15.04.2020

Excel updated on 1st April filtered data.

22 nos. Total claims selected for submitting CAPA.

7 Nos. capa ready and Deepak will submit this to Metso SQE on 15.04.2020.

Till 31st of April remaining CAPA will be submitted

Gaurang will ask 2020 YTD claim list from shanghai

Part Status:
1500120 - 7 pcs (Under fettling, RT OK), UT completed and found okay.
9001438 - 1 pcs under fettling, RT ok. UT also completed and found okay.
9001333 - 5 Nos. Under RT.
Deepak will submit 8D on or before 28th April 2020
Shubham will confirm weather all above items are hipped or not.

Reparing:
Welding repair will be confirmed by Akhatar today.

Process improvement:

Method Changed:
Gating:
Pouring Sheet : Mostly available after Lockdown.
Simulation : -- Deeapk will share simlation (today Deepak will ask CAD personnel
internally and confirm).
Dispatch clearance done by Quality department. 8D is pending but below is information
hipping
for references. or not that is open question. -- Shubham.
added
Hydrogen & Oxygen content checking : Deepak will check this and confirm after
meeting 15.04.2020.
Earlier process :
1. First visual inspection happen 100%.
2. Marking happens.
3. Dispatch.

New process:

1. Machining.
2. Marking.
3. Visual inspection.
4. Dispatch.

Planned but due to lockdown not possible before 4th of May.

PTC hired one person.
Profile : NDT person who is making reports. Informing production people for acceptance
/ rejection.

- Route card can be available at the time of inspection. This process will be start from
4th of May 2020.