Problem/Month Total Problem Category Occurrence

Width 3590 Width 3590

Bore 2205 Bore 2205

Tool mark Tool mark

1437 1437
Flang u/c 1095 Flang u/c 1095
Dent mark 956 Dent mark 956

Track Track
881 881
Flang Width Flang Width 862
862
OD 834 OD 834
D2 u/c 492 D2 u/c 492
Total 12352

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Editing this shape or saving this workbook into a different file format will perma
 Cumulative % Cumulative
3590 29.06
5795 46.92

7232 58.55
8327 674.14
9283 75.15

10164 82.29

11026 89.26
11860 96.02
12352 100.00

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into a different file format will permanently break the chart.

Month Machnining Cost Forgining Cost

Jan-23 7407 129113
Feb-23 3821 77078
Mar-23 4690.38 93643.96
Apr-23 5892.32 90696.76
May-23 3900.98 64337.06
Jun-23 4390.79 57287.14
Jul-23 4449.57 104953.22
Aug-23 5931.31 103042.98
Sep-23 5796.32 93069.08
Oct-23 5977.03 99540.16
Nov-23 5256.26 81280.64
Dec-23 6618.32 78201.09
Total 64131 1072243
 Supplier

Forging

1072243
64131
 Input Process Output
Forging part Rough machining
CNC m/c 1st setup machining
Measuring
2nd setup machining
Instruments
Machined part
Material movement Inprocess inspection
Final inspection
Oiling & packing
Dispatch
Customer

Customer
Sl.No Root Casuse How to identify the Root cause
By knowing the work experience & work
knowledge ( checking the competency & skill
1 Out Butting by operator assessment report)

2 Wrong offset Process monitoring

3 Chuck condition not good

Check the chuck codition by the dial indicator
and chuck recondition report
4 Burr on butting face Incoming inspection

5 Improper Setting of dial

By knowing the work experience & work
knowledge ( checking the competency & skill
6 Improper Setting of machine assessment report)
Sl.No Root Casuse How to identify the Root cause

1 Wrong Offset Process monitoring

Size jump due to clamp screw Process monitoring during the insert change and during
2
loose the inspection
By knowing the work experience & work knowledge
( checking the competency & skill assessment report)
3 Improper Setting of machine

4 Chuck condition not good Check the chuck codition by the dial indicator and chuck
recondition report
Sl.No Root Casuse Occurances Detection
1 Out Butting by operator 9 2

2 Wrong offset 3 6

3 Chuck condition not good 3 2

4 Burr on butting face 8 1

5 Improper Setting of dial 2 1

6 Improper Setting of machine 2 1

Cummulative Sl.No Root Casuse Occurances
11 1 Wrong Offset 3

9 2 Size jump due to clamp screw loose 8

5 3 Improper Setting of machine 2

9 4 Chuck condition not good 3

3
Detection Cummulative
6 9

5 13

1 3

2 5
Sl.No Defect Root Casuse Occurances

1 Width Out Butting by operator 9

2 Width Wrong offset 3

3 Width Burr on butting face 8

4 Bore Wrong Offset 3

Size jump due to clamp

5 Bore 8
screw loose
Detection Cummulative

2 11

6 9

1 9

6 9

5 13
Sl.No Defect Root Casuse

1 Width Out Butting by operator

Wrong offset issues are occurring

2 Width
during the machining process.

3 Width Burr on butting face

Wrong offset issues are occurring

4 Bore
during the machining process.

Size jump due to Shim screw loose

5 Bore
of the shim
 Why1 Why2 Why3

Opeartor not got the exact

The operators might not be accurately Beasuse butting sensor not
judgement of ring butting due to
butting the ring on chuck available
ring size and width on higher side

Because the machined components Because the CNC machine

Because the offset values in the
are not meeting the required operators are giving
CNC machine are incorrect.
specifications. inaccurate offset.

Because of the forgining method

Because the machined components Because the CNC machine

Because the offset values in the
are not meeting the required operators are giving
CNC machine are incorrect.
specifications. inaccurate offset.

Because the shim locking screw

Because the clamp locking screw of
and insert locking screw are
shim loose during the insert change
mounted one upon one sequencs
 Why4 Why5

Because of the lack of

knolwedge and untraine
opeartors

Because of the lack of

knolwedge and untraine
opeartors
Sl.No Root Cause Issue Occurred by this Why
1 Out Butting by operator Beasuse butting sensor not available

Wrong offset issues are occurring Because of the lack of knolwedge and
2
during the machining process. untraine opeartors

Size jump due to clamp screw loose Because the shim locking screw and
3 insert locking screw are mounted one
of the sim
upon one sequencs
4 Burr on butting face Because of the forgining method
 Action Plan
Butting sensor to be Installed to machine
Provide training to CNC machine operators on the importance of accurate offset
values.
Establish a system for documenting and communicating changes to offset values.
Implement checks and double verifications before starting machining operations.

Tool holder to changed from Maxilock S to Maxilock D

Provided training to CNC opeartors on the locking of shim screw also suring the
insrt change
Extra rough operation will carry out after segregate the rings
Project Title Reduce the width and bore
rejection
Transition Owner Umesh A
Plan Date 30.03.2024
Actions Required for completion Action owner

Hollow chuck and butting sensor SS Jadhav

Training to CNC opeartors on the importance SS Jadhav
of accurate offset values.
Communicating changes to offset values sheet Chetan
display

Provided training to CNC opeartors on the Suraj SK

locking of shim screw also suring the insrt
change
Tool holder to changed from Maxilock S to Umesh A
Maxilock D
Scheduled completion Actual completion

28.02.2024

15.02.2024

15.02.2024

15.02.2024

30.03.2024
Problem/Month Total Problem Category Occurrence
Width 72 Width 72
Bore 32 Bore 32
Flang u/c 28 Flang u/c 28
Tool mark 20 Tool mark 20
Flang Width 19 Flang Width 19
Dent mark 18 Dent mark 18
Profile 12 Profile 12
D2 u/c 11 D2 u/c 11
OD 2 OD 2
Groove shift 2 Total 214
Groove ID 1
 Flang
Cumulative % Cumulative Width
Width
Bore Flang u/c D2 u/c

72 33.64 72 19 32 28 11
104 48.60
This chart isn't available in your version of Excel.
132 61.68
152 710.28 Editing this shape or saving this workbook into a different file
chart.
171 79.91
189 88.32
201 93.93
212 99.07
214 100.00
 Dent Tool Case Groove Groove
OD Track Profile Race Pitch
mark mark step ID shift
18 2 0 20 12 0 0 0 1 2

ur version of Excel.

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