Decision ○

Information ●
Instruction ○

Gamma II 1.5 & Kappa 1.2 Cylinder Head Cover Process Audit

Prepared Checked Approved Information Process - audit plan

Inzi Controls - AP

12.05.2022
KMI Engine Quality Control
Ranjith M
 Gamma II 1.5 & Kappa 1.2 Cylinder Head Cover Process Audit
• To Report about the Process audit done By Engine QC on 12 th -05-2022
Objective
• Audit By: Ranjith M Vendor : M/s Inzi Auto components, AP, Part Name : Cylinder Head Cover

Raw
Receiving Injection Baffle plate Final leak PDI
Process Flow Inspection
Material
Molding welding
Baffle leak testing CHC Assy
testing Inspection
Mixing

No Part Line Audit Points Open Closed 4M Observations

1 Raw Material Receiving 3 1 2 Man; 2

2 Injection Molding 1 1 0

3 Cylinder CHC ASSY 4 2 2

Head
Cover Method; 6 Machine; 2
4 Leak testing 2 1 1

Audit Observa- 5 PDI inspection 2 0 2

Materail; 2
tion
Total 12 5 7

Raw Material Mixing CHC ASSY CHC ASSY Leak testing

In Kappa 1.2, Air cleaning before gasket
Weight confirmation of raw material
ASSY not capture in Work instruction.
Mixture (Virgin and return (90:10)) are
(Horizontal Deployment of previous
manual control. Need automation
Customer concern)
Kappa 1.0 TGDI inlet pipe, leak testing
Oil Applying (Poka-yoke) for PCV
traceability not efficient.
Valve O-ring not working.
(Current method only punch mark)
Possibility of improper seating
Need 2D matrix traceability

Conclusion  M/S INZI Should Submit Detailed C/M for above observations on or before 23.05.2022
 Gamma II 1.5 & Kappa 1.2 Cylinder Head Cover Process Audit
NO PROCESS OBSERVATION PHOTO Requirement SUPPLIER PICTURE Target Date Status

Weight confirmation of raw

material Mixture (Virgin and Will discuss with our
Raw Material Automation required to
1 return (90:10)) are manual management Give 30.06.2022 Pending
Mixing confirm the mixing ratio
control. feedback

Mixing Ratio functional

Raw Material failure mode not captured in Functional Failure Mode
2. FMEA 24.05.2022 COMPLETED
Mixing FMEA. need to capture in FMEA

In daily material mixing In the Mixing record, every

Raw Material record, only monitor the
3. lot mixing ratio need to be Microsoft Edge 30.05.2022 COMPLETED
Mixing overall mixing ratio. monitor. PDF Document

In Gamma 1.5, Flash observed End Fill Area Not

Injection To avoid flash mold need to
4 at Oil filler cap area. Possible to Correct the 30.05.2022 Pending
Molding be correct.
Mold

In Kappa 1.2, BR nipple Will discuss with our

Welding turn need to be
welding rotation(Turns) not management Give
5 CHC ASSY capture in Control plan and 28.05.2022 Pending
capture in Control plan feedback
work instruction.
 Gamma II 1.5 & Kappa 1.2 Cylinder Head Cover Process Audit
NO PROCESS OBSERVATION PHOTO Requirement SUPPLIER PICTURE Target Date Status

In Kappa 1.2, Air cleaning

before gasket assy not capture Air cleaning need to be
6 CHC ASSY in Work instruction. capture in Work instruction 24.05.2022 Completed
(Horizontal Deployment of and FMEA.
previous concern)
1.2 IMK CHC CP PMC

Oil Applying (Poka-yoke) for

PCV Valve O-ring not Need 100% oil flow for the 06.06.2022
7 CHC ASSY MET Pending
working. PCV valve.

PCV assembly operator, not

aware about the Oil process & Proper training require for
8 CHC ASSY ASSY 30.05.2022 COMPLETED
not met the required skill level the operator. Foxit PDF Reader
Document

In Final Leak testing report, NG Qty also need to

9 Leak testing NG Qty is not captured mentioned in the Leak ASSY 30.05.2022
COMPLETED
testing report.

In Kappa 1.0 TGDI inlet pipe,

leak testing traceability not
efficient. Need to 2D matrix for Will discuss with our
10 Leak testing 28.05.2022 Pending
(Current method only punch traceability management Give feedback
mark)
 Gamma II 1.5 & Kappa 1.2 Cylinder Head Cover Process Audit
NO PROCESS OBSERVATION PHOTO Requirement SUPPLIER PICTURE Target Date Status

PDI inspector is not inspecting

the part as per the inspection Need inspect part as per TRAINING GIVEN AND COMPLETED
11 PDI Inspection 24.05.2022
standard sequence Sequence. PRACTICED THE INSPECTORS

SEQUENCE TRAINING REPORT.pdf

Q alert not displayed for the

previous customer Q alert need to be
12 PDI Inspection complaint(CHC O-ring 24.05.2022 COMPLETED
display.
damage)
‘Q’ ALERT DISPLAYED IN PDI