ACTION PLAN

K3C Arm assy Kick- Starter- Quality Issues & K0P Arm assy Kick- QIC crack

SL.NO. POINT DISCUSSED Action RESP. Target Dt.

Machine shop set up reports to be verified and final

K3CA Kick arm- Bolt head touching one week time to complete old
1 inspection and PDI data to be checked for bolt Rahul San 20.09.23
parts segg.
head touch issue
100% from top by final insp & 1000% from back
2 K3C Kick arm- Bolt Thread NG 200% inspection with backside side by PDI & from warehouse - separate marking Rahul/Nigam san 19.09.23
to be done
Improvement plan along with evidences will be
3 K3C Kick arm- Overall Improvement plan for warehouse situation Nigam san 22nd Sep
submitted by Nigam san

1. Special fixture to be designed Parveen San/Jaswinder

2. Correction of MPI machine for proper San
4 K0P Kick arm- 100% MPI inspection for outflow 20.09.23
demagnetization and current monitoring - Supplier Yadvinder San
to be contacted for correction - 20.009.23

3 parts will be tested for hardness after quenching

K0P Kick arm & Other modle Hardness testing sample to be scraped
5 process and same will be scrapped - all HMSI parts Devinder San 18.09.23
100%
- record of scrap will be shared on daily basis

OPS/Control plan and rule will be updated for 3

Inspection std, PQCS & OPS revised documents to be shared to parts will be tested for hardness after quenching
6 Devinder/Badal san 20.09.23
HMSI PQ about Scraping the test samples process and same will be scrapped - all HMSI parts
- record of scrap will be shared on daily basis

K0P Kick arm- Raw material supplier change from M/S TK steel to
7 Under discussion with management Kashyap/Jetesh/Vikas san TBC
M/S Arthi (JSW- Material) Supplier c Vishakha, jindal and aar
supplier 5S, material handling, set up and product
8 K0P Kick arm- Billet Tier2 supplier Process Improvement and process parameters data monitoring on daily Kulwant/Rajat san 20.09.23
basis
100% billtet temperature to be checked with laser
9 K0P Kick arm- Billet 100% Temp check before forging gun, check sheet to be implemented and evidence Kulwant/Rajat san 20.09.23
to be shared
supplier called and trial will be done based upon
K0P Kick arm- Water Quenching to be change to Oil Quanching or
10 technical discussion with supplier for oil quenching Kashyap San TBC
Synthatic Polymer Quenching
or Synthetic polymer quenching Quenching media change
What ever action are taken in K3C & K0P has to done HD in other
11 Jitesh san TBC
applicable models. (must)

SYS-F-71, REV. No.-03, Eff, date-31.07.2021

a, jindal and aarti steel

SYS-F-71, REV. No.-03, Eff, date-31.07.2021

 ACTION PLAN
QIC Problem- K0P Kick crack issue, process verification & improvement point.

SL.NO. POINT DISCUSSED Action plan RESP. Target Dt.

Raw Material : No Identification on bars material Lying on floor in mix

Seaparate rack for materialn& tagging
1 condition, No FIFO monitoring, No Lab testing and recording of raw MTL/ Hariom 25.09.23
system
material batch code
Special bin to be made for billet handling and
Billet Cutting/ Shearing: Billet lying on floor. Different size billets found in loading in furnance
2 MTL/ Hariom 25.09.23
heap. (man dependent feed), Roller type arrangement required. Separate area to be identified for billet
shearing

Immediately Laser gun implemented for billet

Heating: Temparature can not be assured on Billets. Man, control
3 temperature monitoring and induction MTL/ Hariom 20.09.23
process. No controlling of temperature. Induction furnace required.
furnace activity plan is attached - 3months
1. part counter to be installed on billet cutting
& trimming machine
Forging: Die Polishing Frequency not decided.Die recut & life not
2. Die polishing freq defined at after every
monitored. Check sheet linkage not available. Part counter to be
4000 parts
4 installed. Chances of missaligned. Parting line width is 3.5 mm but as per MTL/ Hariom 20.09.23
3. die month code will be changed after 25th
3D model it is required 2 mm max Aug month batch code marking on
of every month
Forging.
4. Model sent to supplier will be checked for
1. Die polishing
parting line widthfreq defined after every 7000
Trimming : Die Polishing frequency not decided. Die recut & Life not no's or considering part condition
5 monitored. Check linkage not availble. Material accumulated- chances of 2. Conveyor system will be implemented with MTL/ Hariom 20.10.23
cold Trimming. Single piece flow required- (By Conveyor) in target time of 1.5 month - activity plan is
attached
1. Loading to furnance time -> Furnance to
just before quenching start -->
Quenching time --> Devinder San
Tempering time -->
Heat Treatment: Spec: 37 min Act: 80 min- Need to be revalidated. In 21.09.23
2. Oil quenching/synthetic polymer Kashyap/Yadvinder San
6 check sheet, supervisor filled 37 min. Oil Quenching required for better
quenching option under consideration -
results. Temperature control alarm should be limked with Thermocouple.
supplier visit is planned - activity plan is
attached Yadvinder San
3. Temperature control alarm linkeage done
with thermocouple

Hardness machine will be shifted to

quenching area - Yadvinder san - 20.09.23
Hardness (After Hardening ): Part handling rule to avoid mixing with --> Paint standardisation for quenching and
7 tempering part colour coding system at quenching and tempering station tempering area to be done - Devinder San - MTL 20.009.23/21.09.23
and at hardening machine for part handling 21.09.23
--> Set up part handling rule will be changed
- Badal San - 20.09.23

MPI: Part not magnetize properly due Holding in copper wire and in loose 1. Part testing directly with electrode contact
condition.Both end electrode clamping required. Also can not be check started
8 Parveen/Devinder/Jaswinder san
by single machine. FPR 100% MPI- More setups require Capacity need 2. Special fixture will be made for capacity
to revalidated. enhancement

Microstructure testing started for 1 pcs per lot

Lab testing: Microstructure freq 1 pcs per lot. Micro vicker Hardness
9 and micro vicker hardness testing will be Devinder/Badal San 22.09.23
need to be added for assurance of hardness.
started by 22.09.23

Other Points

SYS-F-71, REV. No.-03, Eff, date-31.07.2021

 Tool life monitoring of machine shop not available - part counter need to
be installed on all the machine.

K1K- Kick QAV countermeasure status: Total Points = 12 nos,

MTL 17.09.2023
Implemented 8 nos, Improvement required = 4 nos.

Shop floor 3'S of Forging shop and Machine shop was not Good at Tier 5S will be improved of shop floor with proper
MTL / Hariom 30.09.23
2- M/S Hariom Auto. material handling & identification system

Check points will be added in PQCS/SOP/WI

All check point need to be added in PQCS & SOP and work instruction. MTL / Hariom
upon completion

PPE'S not availble in forging shop- Helmet, Safety Shoes and Gogles. PPE will be provided in one week time Hari Om 25.09.23

SYS-F-71, REV. No.-03, Eff, date-31.07.2021