Process Control Analysis - New Plant... 15.11.21

PROCESS CONTROL ANALYSIS - NEW PLANT ( 09.09.21 TO 19.09.
21 )
DATE DEFECT REASON ACTIONS STATUS REMARKS
A-L&T-03 undermaintenance due to step problem. 1-Alignment done to remove the step. Frequent Alignment out &
09.09.21 OPEN SPLICE Corrected
B- 12.00-24 production loss due to hydroulic pipe leackage 2- Knife-cleaning was done Knife-cleaning neglected
L&T-03 stepping problem due to mis-alignment corrected by adjustment and 1-Alignment done to remove the step. Frequent Alignment out &
Knife was found not clean 2- Knife-cleaning was done Knife-cleaning neglected
Low gauge due to low weight thus pressure of the clamp was making the the
1- extra paint application Frequent guage variation to be
10.09.21 OPEN SPLICE tube slipped causing the defect , extensive oil application showed Corrected
2-Die & Mendrel were got machined controlled
improvements and die-mendrel send for machining to mitigate guage variation
L&T-03 stepping problem due to mis-alignment corrected by adjustment and

11.09.21 OPEN SPLICE alignment done to remove the step Corrected Alignment out
Knife was found not clean
L&T-05stepping problem due to mis-alignment corrected by adjustment and 1-Alignment done to remove the step Frequent Alignment out &
Knife was found not clean 2- Knife cleaning was done. Knife-cleaning neglected
L&T-03 stepping problem due to mis-alignment corrected by adjustment and

16.09.21 OPEN SPLICE alignment done to remove the step Corrected Alignment out
Knife was found not clean
L&T-03 stepping problem due to mis-alignment corrected by adjustment and 1-Alignment done to remove the step Frequent Alignment out &
Knife was found not clean 2- Knife cleaning was done. Knife-cleaning neglected
Solders surfaces were contaminated by burnt rubber as Knife-cleaning was not 1-Knife-cleaning was done Knife & Solder cleaning to be
11.09.21 SPLICE CRACK Corrected
done & solder too found not clean 2-Solders were cleaned by emary paper focussed
L&T-05 operator was not performing the soldring adequately and hot surface & 1-Knife-cleaning was done Knife & Solder cleaning to be
Knife were not clean. 2-Solders were cleaned by emary paper focussed
10.09.21 WEAK SPLICE L&T-04 tube was getting slipped alignment done to remove the step Corrected First sample to be checked
W/s & O/s - fab o mech problem,high heat of knife before 1'' of appoach and 1-put under electrical maintenance 1-Fine-tuning was needed
10.09.21 WEAK SPLICE Corrected
knife high speed problem and Knife was found not clean 2-Knife-cleaning was done 2-Knife-cleaning neglected
13.09.21 THIN SIDE 175/65 R 14,5.00-12 mould gap adjust - corrected Gap was adjusted Corrected FTC needs to be filled
operator was not inflating the tube on shaper upto the limit, the tube was loaded Operator was instructed to shape the tube Operator negligence
14.09.21 THIN SIDE upto Limit set. Corrected
loosely.
operator was not inflating the tube on shaper upto the limit, the tube was loaded Operator was instructed to shape the tube
15.09.21 THIN SIDE upto Limit set. Corrected Operator negligence
loosely.
16.09.21 THIN SIDE 12.5/80-18 Mould inherent complexities green tubes were re-extruded Corrected FTC needs to be filled
18.09.21 THIN SIDE condenset problem Put under maintenance Corrected ----
185/70 R 14 gauge problem top - bottom difference required was 0.8 mm but
found 1.00 mm thus bottom guage was less then reqiired and top guage was bit Frequent guage variation to be
11.09.21 THIN SPOT Tube was re-extruded Corrected
more then required - another tube was extruded and cured, problem corrected - controlled
operator problem
Width-buckle was found as there was hinderence in piston movement of curing-

10.09.21 BUCKLE Put under maintenance Corrected FTC needs to be filled
press due to hydraulic leakage
12.00-24 , Width-buckle as tube was getting loose-shaped on shaper as per
11.09.21 BUCKLE Shaping time on shaper was reduced Corrected ----
shaping-time.
9.00-20CB,7.50-16 Width-buckle as tube was getting loose-shaped on shaper
13.09.21 BUCKLE Shaping time on shaper was reduced Corrected ----
as per shaping-time.
14.09.21 BUCKLE Operator lapse, he was loading the tube 7.50-16 correctly Operator was counselleds and CB were put --- Operator negligence
for curing
F78-15 buckle problem due to elongated lengthso 05 mm splice length
18.09.21 BUCKLE Green-tube length was reduced by 05 mm Corrected ----
reduce………corrected
A-7.50-16 tubes found with Width-buckle due to Flat-widthin excessso tube
19.09.21 BUCKLE Corrected Operator negligence
segregation------corrected Tubes were seggregated for correct F-width
Salvage valve painting needs

09.09.21 VALVE CRACK due to salvage valve usage Application of thickened paint Corrected
improvement
10.09.21 VALVE CRACK Usage of salvage valves Application of thickened paint Corrected
improvement
11.09.21 VALVE CRACK Usage of salvage valve usage,corrected by thick paint application Application of thickened paint Corrected
improvement
100 mm embosed patches were not available thus for 3 hrs valves were Embosed patches were got issued Loose issue from stores
14.09.21 VALVE CRACK Corrected
covered with three patches of 80 mm on big valves TR177 / 78 etc.
15.09.21 BODY BILISTER Material comosition fine-tunning green tubes were re-extruded Corrected FTC needs to be filled
12.5/80-18 operator was inflating excess air thus tube was getting sandwitched Tube inflation was made limited upto limit
15.09.21 MOULD PINCH Corrected Operator Lack of awareness
between mould-parts and applied with powder.
19.09.21 MOULD PINCH Shaping was not being done correctly. Operator was counselleds and shaping was Corrected Operator negligence
corrected.
15.09.21 NO INTERNAL mould nozzle was found disturbed. Nozzle of the Mould was re-aligned Corrected FTC needs to be filled
SCRAP TRENDS- NEW PLANT REPAIR ANALYSIS - NEW PLANT

4.5 14
4 12
3.5 10
3 8
% REPAIR
% SCRAP
2.5 6
2 4
1.5
2
1
0
0.5
08/09
09/09
10/09
11/09
13/09
14/09
15/09
16/09
18/09
19/09
0
08/09 09/09 10/09 11/09 13/09 14/09 15/09 16/09 18/09 19/09
Comments
1 Scrap & Repair exhibit consistency in B-shift indicating process in control in preceeding shift.
2 Scrap trends abruption in A-shift indicating weaker process control in B-shift.
3 Repair trends major abruption in A-shift again indicates weaker process control in B-shift.
Improvement points suggessted

1 Splicer -clamp area alignments get frequently disturbed-rhobust fine tuning needed.
2 Knife & Solder cleaning to be focussed.
3 Operatore negligence particularly fake reporting pertaining to Knife & solder monitoring needs to be cared.
4 When a new size gets started first tube check -- FTC needs to be performed.
5 Salvage valves painting needs to be strengthen
6 Operators awareness needs to be improved pertaining to Bulge / Mould pinch for defect-minimization.
7 Valve-painting needs to be further improved i.e. Isolation / cleaning of trays / dust contamination needs further control.
8 Embosed patches supply planning needs improvements and patches of right size to be supplied on right time.
PREPARED BY APPROVED BY
MANAGER - QUALITY GM - TECHNICAL

S. no. OBSERVATIONS FOUND RESPONSIBILITY
1 Splicer -clamp area alignments get frequently disturbed-rhobust fine tuning needed. MAINTENANCE
2 Knife & Solder cleaning to be focussed. PROD
Operatore negligence particularly fake reporting pertaining to Knife & solder monitoring
3 needs to be cared.
HR / PROD
4 When a new size gets started first tube check -- FTC needs to be performed. PROD / QA
5 Salvage valves painting needs to be strengthen PROD
Operators awareness needs to be improved pertaining to Bulge / Mould pinch for
6 defect-minimization. PROD / QA
Valve-painting needs to be further improved i.e. Isolation / cleaning of trays / dust

7 contamination needs further control. PROD
Embosed patches supply planning needs improvements and patches of right size to be
8 supplied on right time.
STORES
REPAIR ANALYSIS FOR TODAY : NEW PLANT (Shift-A)
REPAIR ( %)
DATE REASONS RESPONSIBLE PERSONS REMARKS ACTION PLANS
NAME Nos
Body blister 25 Material & atmosphere effects ---- ---- ----
27.09.21 Splice crack 21 Solder temperature problem Electrical maintenance Corrected Solder checking on Plant/off
Newly deployed person did not HR requested to not to deploy

Valve crack 09 Manpower management Run under supervision
paint correctly stranger persons
PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

PARAM. SCRAP REPAIR PRODUCTION REMARKS
Nos 19 83 1781 ---
Kg 28.8 ---- 2814.5 ---
The repair has been figured as 4.6% , accomodating the Blister effects
% 1.02 4.6 ---- which may be caused due to sesonal-material effects .If the same is
excluded the repair occurance is 3.25 % .
SCRAP ANALYSIS FOR TODAY : NEW PLANT (Shift-A)
SCRAP ( %)
NAME Nos
17.5-25 Tubes under went burning On job counselling and

BURNT 03 Curing operator & Helper Loading method to be monitored
due to faulty loading in mould training
28.09.21
17.5-25 Tubes under went No-
POWER FAIL 02 ---- ---- ----
internal due to power failure
OPEN MOULD 01 7.50-16 CB Maintenance Corrected ----
REPAIR ANALYSIS FOR TODAY : NEW PLANT (Shift-A)

REPAIR ( %)
NAME Nos
Valve crack 15 Old painted valve used ---- ---- ----
Splice crack 15 LT-3 Wrinkle problem Electrical maintenance Corrected Damaged clamp needs to be
28.09.21 changed
FM 09 Seasonal effects & Insects ---- Run under supervision ----

Nos 21 84 1644 ---
Kg 61 ---- 3071 ---
% 1.98 5.1 ---- The repair contains 15 no of valve-cracks on account of Old-valves usage
REPAIR ANALYSIS FOR TODAY : NEW PLANT (Shift-A) 74.13793
REPAIR ( %)
NAME Nos
Compound behaviour may be one
Body blister 29 Technical / QA --- Fine tuning to be done
of the reasons
29.09.21 Splice crack 25 LT-3 Rubber-jaw problem Electrical maintenance to be corrected Diagnostic replacement
FM 20 Seasonal effects & Insects ---- Run under supervision ----
Valve crack 19 Old painted valve used ---- ---- ----

Nos 46 110 1784 ---
Kg 45.6 ---- 3113 ---
% 1.46 6.16 ---- The repair contain Body Blister / FM constituting major part of repair.
RPAIR ANALYSIS FOR TODAY : NEW PLANT (Shift-A)
SCRAP ( %)
NAME Nos

Nos ---
Kg ---
%
0.917431
4.370761
SCRAP ( %)
NAME Nos
1- Nozzle alignment corrected
1- Nozzle mis-alignment 2- Powder application to be focussed before 1- Nozzle inspection in start of shift
13.10.21 Buckle 24 PROD / QA / MAINT
2- Operation Lapse loading the tube in press as wt running is at lower 2-Powder application
side as per CSR

Nos 44 --- 1489 ---
Kg 61.3 --- 1765 ---
% 3.47
SCRAP ( %)
NAME Nos
Open splice 10 Step problem in LT- 3 & 5 Maintenance Clamp alignment was got corrected Sample inspection- in practice
14.10.21
Buckle 06 Operator loading problem PROD / QA Operator counselling and vigilance Followup with Inspection & correction

Nos 31 --- 1509 ---
Kg 50.15 --- 1813 ---
% 2.77 --- --- ---

SCRAP ( %)
NAME Nos
Width buckle 16
1-Seasonal effects due to ambient
1-Followup with Inspection & correction
temperature change --- ---
19.10.2021 2-Shaping problem made by operator 2- Shaping under supervision
Mould pinch 10
Open mould 13 Moulds change and set-up Maintenance --- Moulds were reloaded after Lapping

Nos 59 --- 1650 ---
Kg 115.5 --- 2456 ---
% 4.7 --- --- ---
SCRAP ( %)
NAME Nos
1-Seasonal effects due to ambient temperature change 1-Followup with Inspection & correction
Buckles 20 2-Shaping problem made by operator PROD / QA --- 2- Shaping under supervision
1-Solinoid valve of Curing press-05 was malfunctioning 1-MAINTENANCE 1-Solinod-valve was rectified.
21.10.2021 No Internal 07 ---
2-Operation Lapse as valve was not properly into nozzle 2-OPERATIONAL LAPSE 2-Followup with Inspection & loading
Open splice 12 L&T-3 : Fluctuation in High-heat causing the defect ELECTRICAL --- Electrical problem was rectified.

Nos 59 --- 1865 ---
Kg 89.4 --- 2722.38 ---
% 3.28 --- --- ---
SCRAP ANALYSIS FOR TODAY : MOTOR CYCLE PLANT (Shift-A)

SCRAP ( %)
NAME Nos
Crack splice 95 Over inflation of the hot -tube before core-fixing OPERATION LAPSE --- 2- Colling of the cured tube & inflation
under supervision
21.10.2021
Open splice 53 Step problem exhibited in Splicer machines --- 1-Stepping was corrected.
1-L&T-02
MAINTENANCE/ ELCTRICAL 2-The clamp was changed in FOB-01
2-FOB-01
Weak splice 19 3-FOB-04 --- 3-In FOB-04 step and over-hang was corrected
PROCESS PERFORMANCE FIGURES FOR TODAY MOTOR CYCLE PLANT (Shift-A)

Nos 171 95 3322 ---
Kg 75.7 --- 1426 ---
% 5.3 --- --- ---
SCRAP ( %)
NAME Nos
Thin side 10 Operator was not loadind the tube properly Operation lapse Followup with Inspection & correction
---
22.10.2021 Open splice 9 There was wrinkle problem exhibited in L&T-3 Maintenance M/c was attended and corrected
Valve buckle 6 Operator was not loadind the tube properly Operation lapse --- Followup with Inspection & correction

Nos 44 --- 1710 ---
Kg 86.2 --- 2306 ---
% 3.72 --- --- ---

SCRAP ( %)
NAME Nos
Width buckle 21 The shaping time was lesser then that required Operation lapse --- Operator was counselled and corrected
Open splice 22 Stepping problem in FOB 1& 4 Maintenance M/c was attended and rectified
23.10.2021 1-Operator was told to set the right alignment between

1-Operation lapse nozzle & valve correctly.
No internal 13 Operation lapse and Internal miss 2-Maintenance ---
2-Maintenance got the miss corrected.
Body blister 14 Nip-blisters and seasonal effects --- --- ---

Nos 149 33 2764 ---
Kg 68.24 --- 1273.5 ---
% 4.5 --- --- ---
SCRAP ( %)
NAME Nos
Thin side 10 Operator was not loadind the tube properly Operation lapse Followup with Inspection & correction
---
23.10.2021 Open splice 9 There was wrinkle problem exhibited in L&T-3 Maintenance M/c was attended and corrected
Valve buckle 6 Operator was not loadind the tube properly Operation lapse --- Followup with Inspection & correction

Nos 44 --- 1710 ---
Kg 86.2 --- 2306 ---
% 3.72 --- --- ---

SCRAP ( %)
NAME Nos
Width buckle 21 The shaping time was lesser then that required Operation lapse --- Operator was counselled and corrected
Open splice 22 Stepping problem in FOB 1& 4 Maintenance M/c was attended and rectified
23.10.2021 1-Operator was told to set the right alignment between

1-Operation lapse nozzle & valve correctly.
No internal 13 Operation lapse and Internal miss 2-Maintenance ---
2-Maintenance got the miss corrected.
Body blister 14 Nip-blisters and seasonal effects --- --- ---

Nos 149 33 2764 ---
Kg 68.24 --- 1273.5 ---
% 4.5 --- --- ---
SCRAP ( %) RESPONSIBLE
DATE REASONS REMARKS ACTION PLANS
NAME Nos PERSONS
Open splice 03 Knife cleaning in-adequate
--- 1-knife-cleaning/ soldering / painting to be more focused
25.10.2021 Weak splice 02 Soldering and painting reasons Operation lapse 2-Followup with Inspection & correction
Valve buckle 04 In-correct Nozzle & Valve alignment ---

Nos 25 --- 1388 ---

Kg 37.8 --- 2158 ---
% 1.75 --- --- ---

NAME Nos PERSONS
Splice open 16 Stepping problem in LT-2 due to end-block mis-alignment Maintenance Corrected ----
N/Body blister 15 Seasonal effects and Feed- width not fine-tuned. Tech / QA --- Feed-width to be reviewed
25.10.2021
Maintenance has been working on the fine-matching of
open mould 12 In 2.75-18 due to mis-match of mould parting lines Maintenance Under rectification moulds
Buckle 15 Erratic loading by operators Operational lapse --- Followup with Inspection & correction

Nos 92 06 3429 ---

Kg 40.9 --- 1576 ---
% 2.6 --- --- ---
NAME Nos PERSONS
Open splice 07 Knife cleaning in-adequate 1-knife-cleaning/ soldering / painting to be more focused
26.10.21 Operation lapse ---
Width buckle 02 Delayed loading of the tube in mould by operator 2-Followup with Inspection & correction

Nos 42 --- 1441 ---

Kg 59.6 --- 2092 ---
% 2.85 --- --- ---

NAME Nos PERSONS
1-Extreemly diluted Slicon application was started
25.10.2021 N/Body blister 15 Excess silicon application at Strainer and Extruder head Prod / QA ---
2- Aprox 2500 green tubes were hold for rework.

Nos 83 55 1839 Production was hindered at 5 am in morning as the Conveyor belt was
Kg 36.5 --- 792 broken , resumed at 12 pm noon
% 4.61 --- ---
NAME Nos PERSONS
Open splice 08 New man-power deployment on LT-4 & 5 Absentism
1- Skilled manpower to be deployed
27.10.21 --- 2-Followup with Inspection & correction
1-Late loading made by operator
Thinside 11 Operation lapse
2-Erratic loading in 9.00-15 in radial mould

Nos 43 --- 1336 ---

Kg 74.5 --- 1971 ---
% 3.78 --- --- ---

NAME Nos PERSONS
Extreemly diluted Slicon application was started and being run
N/Body blister 15 Excess silicon application at Strainer and Extruder head Prod / QA ---
under observation
27.10.21
Open splice 21 Stepping problem in L & T-2 due to mis-alignment Maintenance --- End-block alignment was streamlined

Nos 99 45 2568
---
Kg 44.6 --- 1166
% 3.82 --- ---
NAME Nos PERSONS
buckle 10 Operator was not loading the tube properly Operation lapse
28.10.21 --- Followup with Inspection & correction
1-Late loading made by operator
Thinside 16 Operation lapse

Nos 51 --- 1390 ---

Kg 83.9 --- 2040 ---
% 4.11 --- --- ---

NAME Nos PERSONS
buckle 16 Operator was not loading the tube properly Operation lapse --- Followup with Inspection & correction
28.10.21
Open splice 13 Stepping problem in L & T-2 due to mis-alignment Maintenance --- End-block alignment was streamlined

Nos 84 73 3038
---
Kg 40.1 --- 1345
% 2.9 --- ---
NAME Nos PERSONS
Thin side 23
New operator deployment causing eratic loading Operation lapse Lack of awareness Followup with Inspection & correction
Buckle 21
29.10.21 In splicers there are wide openings on body and at operator
Open splice 07 side at the exit of the knife- current variation or some Electrical dept --- Electrical reasons yet to be fixed
irregularity may be probable cause

Nos 68 --- 1583 ---

Kg 168.4 --- 2482 ---
% 6.8 --- --- ---

NAME Nos PERSONS
Splice-open 13 Stepping problem in LT 1 & 2 due to new operator deployment Operation lapse --- Followup with Inspection & correction
1-Excess mould gap 1- Mould gap was adjusted

29.10.21 Mould pinch 12 --- ---
2- GT length contraction 2- The Length of was increased by 20 mm.
Valve blister 9 Contamination by steam-water particles in new painting-room --- --- ---

Nos 80 32 3000
---
Kg 34.4 --- 1314
% 2.62 --- ---
NAME Nos PERSONS
Valve buckle 09
Newly recruited operator deployment causing eratic loading Operation lapse Lack of awareness Followup with Inspection & correction
30.10.21 Mould pinch 06
-- -- -- -- --- --

Nos 36 --- 1419 ---

Kg 73.9 --- 2564 ---
% 2.88 --- --- ---

NAME Nos PERSONS
Splice-open 12 Stepping problem in LT 1 & 2 due to new operator deployment ---
Operation lapse
Buckles 15 Excess inflation of the tube on the shapers ---
30.10.21 Followup with Inspection & correction
Body blister 06 Excess-Silicon contaminated work-away being used as work-away --- ---

Nos 73 38 2920
---
Kg 29.5 --- 1243
% 2.37 --- ---
NAME Nos PERSONS
Buckle 09
Newly recruited operator deployment causing eratic loading Operation lapse Lack of awareness Followup with Inspection & correction
Thin side 06
31.10.21
Operation lapse due to
Valve blister 06 Wrong method of valve-painting on reused valves --- One more operator/ Helper needs to be developed
Absentism

Nos 28 --- 1371 ---

Kg 54.1 --- 2283 ---
% 2.37 --- --- ---

NAME Nos PERSONS
Splice-open 11 Stepping problem in LT -2 due to mis-alignment Maintenance --- Attended and corrected
31.10.21
Body blister 08 Excess-Silicon contaminated work-away being used as work-away --- --- ----

Nos 78 40 3270
---
Kg 36.2 --- 1420
% 2.55 --- ---
NAME Nos PERSONS
Buckle 26 1-Followup with Inspection & correction
Operation lapse as operators were not performing the loading properly Operation lapse Lack of awareness
01.11.21 Thin side 17 2-More of operator/ Helper needs to be developed
--- -- -- -- --- ---

Nos 40 --- 1729 ---

Kg 88 --- 2720 ---
% 3.24 --- --- ---

NAME Nos PERSONS
Stepping problem in LT -2 and FOM-1 due to mis-alignment of end-blocks
Splice-open 21 Maintenance --- Attended and corrected
& clamps.
01.11.21
Tubes were saggregated, wrong moulded tubes were
Buckles 26 Tube-mixup problem due to lack of awareness Operation lapse ---
scrapped

Nos 99 53 4100
---
Kg 48.2 --- 1811
% 2.66 --- ---
NAME Nos PERSONS
Operation lapse as operators were not performing the loading properly

Thin side 33 1-Cycle time for shaping was not completed but tube was loaded. Operation lapse Lack of awareness
02.11.21 2-More of operator/ Helper needs to be developed
2- Erratic seating of the tube in the mould
--- -- -- -- --- ---

Nos 63 --- 2065 ---

Kg 106.7 --- 3391 ---
% 3.15 --- --- ---

NAME Nos PERSONS
Splice-open 22 Stepping problem in LT -2 due to mis-alignment of clamps. Maintenance --- Machine was attended
02.11.21
Buckles 28 Erratic seating of the tube in the mould Operation lapse ---
2-More of operator/ Helper needs to be developed

Nos 120 61 4686

---
Kg 55.3 --- 2138
% 2.59 --- ---
DATE REASONS PERSONS REMARKS ACTION PLANS
NAME Nos
Thin side 08 Operation lapse as operators were making erratic seating of the tube 1-Followup with Inspection & correction
03.11.21 in the mould. Operation lapse Lack of awareness 2-More of operator/ Helper needs to be developed
Buckle 09

Nos 40 --- 1117 ---

Kg 63 --- 1808 ---
% 3.48 --- --- ---

NAME Nos PERSONS
1-Stepping problem in LT -2 & 1 due to mis-alignment of clamps.
Splice-open 22 2- The end-block of LT -1 was damaged Maintenance --- Machines were attended and corrected.
03.11.21
Buckles 23 Erratic seating of the tube in the mould Operation lapse --- 2-More of operator/ Helper needs to be developed

Nos 111 39 2387

---
Kg 49.1 --- 1174
% 4.57 --- ---
NAME Nos PERSONS
It was persisting in Cavity 247/7.50-16 due to The green-tube was extruded with Flat-width
Thin side 09 Mould fabrication ---
specific mould geometry increased by 2 mm, corrected.
In the splicer LT-3, the clamp was exhurting

12.11.21 Pinch splice 06 Maintenance --- Clamp-gap adjusted and problem corrected.
excessive pr on the tube.
The coller of the shaper was applied with rubber on

The defect occurred in 5.20-14 / Cavity 49
Buckle 04 --- --- the coller area there-after tube was shaped and the
due to shaper ambiguity
defect was seized.

Nos 37 --- 1359 ---

Kg 47.9 --- 2028 ---
% 2.36 --- --- ---

NAME Nos
Body-blister 53 Nip-blisters and seasonal effects --- --- ---
Buckles 57 1-Followup with Inspection & correction

12.11.21 Erratic seating of the tube in the mould Operation lapse ---
2-More of operator/ Helper needs to be developed
Thin side 47
Stepping problem in FOMc - 1/2/4 due to mis-
Open splice 22 Maintenance --- The alignment was rectified and defect was controlled
alignment.

Nos 287 89 4251

---
Kg 105.6 --- 1900
% 5.56 --- ---
NAME Nos PERSONS
The green-tube Blue-line was kept away from

Splice open 10 It was persisting in LT-3 & 4 machines. --- ---
operator-side then spliced, defect got controlled.
13.11.21 Operator - Ajay Pal does not load the tubes

Buckle 13 correctly Operation lapse --- He will be counselled to correct the operation.
12.00-24 was found with low wt 3.730/3.780

Thin side 05 i.p.o. 3.9 kg --- --- Tube with adequate wt was deployed for curing

Nos 43 --- 1825 ---

Kg 63.7 --- 2885 ---
% 2.21 --- --- ---

NAME Nos PERSONS
Thin side 29 Difficulty in Shaping due to cold weather --- --- Followup with Inspection & correction
13.11.21 Stepping problem in LT-2 due to
mis-alignment of clamp.

Nos 131 77 4571

---
Kg 54.9 --- 2009
% 2.73 --- ---
NAME Nos PERSONS
The Shaper stopper got disturbed thus inflation
14.11.21 Thin side 07 --- --- The stopper was adjusted and defect got controlled
went lower causing the defect

Nos 27 --- 1825 ---

Kg 43 --- 2885 ---
% 1.85 --- --- ---

NAME Nos PERSONS
buckle 58 Difficulty in Shaping due to cold weather --- --- Followup with Inspection & correction
14.11.21 Stepping problem in LT-2 due to
Open splice 34 mis-alignment of clamp. Maintenance --- The alignment was rectified and defect was controlled

Nos 106 77 4571

---
Kg 44.8 --- 2009
% 2.55 --- ---
NAME Nos
It was persisting in LT-3 due to damaged clamp as

Splice open 15 Maintenance --- The damaged clamp was replaced.
replacement was lagging the schdule.
15.11.21
Buckle 06
Operators donot not load the tubes correctly Operation lapse --- Operator was counselled to correct the operation.
Thin side 11

Nos 51 --- 1658 ---

Kg 90.7 --- 2796 ---
% 3.2 --- --- ---

NAME Nos PERSONS
15.11.21 Buckle 40 Difficulty in Shaping due to cold weather --- --- Followup with Inspection & correction
Stepping problem in LT-2, FOM-2 due to

Open splice 34 mis-alignment of clamp. Maintenance --- The alignment was rectified and defect was controlled
Thin side 16 Operators donot not load the tubes correctly Operation lapse --- Followup with Inspection & correction

Nos 119 66 5519

---
Kg 54.6 --- 2456
% 2.22 --- ---
NAME Nos
Splice open 09 It was persisting in LT-4 due to slippage of green-tube. Maintenance --- The clamp was realigned and defect generation got stopped.
16.11.21
Buckle 07 Operators donot not load the tubes correctly Operation lapse --- Operator was counselled to correct the operation.

Nos 27 --- 1257 ---

Kg 33.6 --- 1574 ---
% 2.13 --- --- ---

NAME Nos PERSONS
16.11.21 Open splice 34 mis-alignment of clamp. Maintenance --- The alignment was rectified and defect was controlled

mis-alignment of clamp.
16.11.21 Buckle 40 Difficulty in Shaping due to cold weather --- --- Followup with Inspection & correction
Thin side 16 Operators donot not load the tubes correctly Operation lapse --- Followup with Inspection & correction

Nos 159 73 5392

---
Kg 76.6 --- 2409
% 3.18 --- ---

Process Control Analysis - New Plant... 15.11.21

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PROCESS CONTROL ANALYSIS - NEW PLANT ( 09.09.21 TO 19.09.

L&T-03 stepping problem due to mis-alignment corrected by adjustment and

L&T-03 stepping problem due to mis-alignment corrected by adjustment and

Width-buckle was found as there was hinderence in piston movement of curing-

Salvage valve painting needs

SCRAP TRENDS- NEW PLANT REPAIR ANALYSIS - NEW PLANT

Improvement points suggessted

MANAGER - QUALITY GM - TECHNICAL

Valve-painting needs to be further improved i.e. Isolation / cleaning of trays / dust

Body blister 25 Material & atmosphere effects ---- ---- ----

Newly deployed person did not HR requested to not to deploy

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

Nos 19 83 1781 ---

Kg 28.8 ---- 2814.5 ---

17.5-25 Tubes under went burning On job counselling and

REPAIR ANALYSIS FOR TODAY : NEW PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

REPAIR ANALYSIS FOR TODAY : NEW PLANT (Shift-A) 74.13793

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

% 2.77 --- --- ---

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

SCRAP ANALYSIS FOR TODAY : MOTOR CYCLE PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY MOTOR CYCLE PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

SCRAP ANALYSIS FOR TODAY : MOTOR CYCLE PLANT (Shift-A)

23.10.2021 1-Operator was told to set the right alignment between

PROCESS PERFORMANCE FIGURES FOR TODAY MOTOR CYCLE PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

SCRAP ANALYSIS FOR TODAY : MOTOR CYCLE PLANT (Shift-A)

23.10.2021 1-Operator was told to set the right alignment between

PROCESS PERFORMANCE FIGURES FOR TODAY MOTOR CYCLE PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

Nos 25 --- 1388 ---

SCRAP ANALYSIS FOR TODAY : MOTOR CYCLE PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY MOTOR CYCLE PLANT (Shift-A)

Nos 92 06 3429 ---

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

Nos 42 --- 1441 ---

SCRAP ANALYSIS FOR TODAY : MOTOR CYCLE PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY MOTOR CYCLE PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

Nos 43 --- 1336 ---

SCRAP ANALYSIS FOR TODAY : MOTOR CYCLE PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY MOTOR CYCLE PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

Nos 51 --- 1390 ---

SCRAP ANALYSIS FOR TODAY : MOTOR CYCLE PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY MOTOR CYCLE PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

Nos 68 --- 1583 ---

SCRAP ANALYSIS FOR TODAY : MOTOR CYCLE PLANT (Shift-A)

1-Excess mould gap 1- Mould gap was adjusted

PROCESS PERFORMANCE FIGURES FOR TODAY MOTOR CYCLE PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

Nos 36 --- 1419 ---

SCRAP ANALYSIS FOR TODAY : MOTOR CYCLE PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY MOTOR CYCLE PLANT (Shift-A)

PROCESS PERFORMANCE FIGURES FOR TODAY NEW PLANT (Shift-A)

Nos 28 --- 1371 ---