CRANK SHAFT (BR10) PIN COLLAR

DEFORMATION
(BRAZIL PLANT)

PWT#2 | 05 / 04 / 2017
QC STORY : Pin-2 Deformation & Width Over size

8.Conclusion,Review & Future Actions

7.Standardization

6.Result Checking

5.Implementation of Countermeasures

4.Determination of Countermeasures

3.Factor Analysis

2.Grasping Current Condition & Target Setting

1.Problem Description
1. Problem Description :

Engine Abnormal Noise during Engine Testing @ FTB in Brazil Plant.

Qty : 1No. (PIR : 201600470357)
 Concern Parts Produce Date
Concern Reported Date : 05.12.2016  25-Jun-2016
Cause : PIN 2 Collar Deformation.  02-07-2016
Pin Width : 20.574+0.4 / Derogation : 21.354
The parts found up to 22.07 mm due to deformation.

Collar Deformation
2.Grasping Current Condition

1. Rejection Status – Pin Collar Deformation

50
After
Total – 43 no’s Brazil Burza
Sorting
40 Month
11
FTB Dec’16 Jan – Mar’17 Up to Mar’17
30 Noise Total
BURZA
20 BRAZIL
After
31 At FTB After Sorting At FTB
Sorting
10 Qty
1 1 31 0 11 43
0
Dec'16 Jan to Mar'17

2. Rejection Status – Wall Thickness Less & Offset

- 221Nos Parts NOK Parts kept hold – Product Replied OK

 Informed to Brazil to use these

CS QA REPLY.msg
Parts on 09.12.16

Weekly Meeting with CMO.msg Linear Feedback.JPG Before Cutoff parts – 15.12.16
2.1 Brazil – Pin Deformation Concern part Inspection Summary

Total Parameter OK Within Derogation NG Remarks

Derogation
Pin#2 Width at Top side Exceeded
90 84 5 1
Derogation limit of 21.354

Inspection Report
2.2 Export Concern parts Details
EXPORT CONCERNS PARTS

PIN-1 PIN-2 PIN-3

SL NO PART NO REMARKS
G.E Width PHOTO F.E Width G.E Width PHOTO F.E Width G.E Width PHOTO F.E Width

1 176-0044 3.1 2.65 3.29 1.37 3.97 1.93

2 183-0107 3.46 2.21 3.29 1.13 4.29 1.8

3 176-0079 3.6 2.76 3.37 1.26 3.95 2.24

4 176-0073 3.15 2.74 3.41 1.39 4.14 2.11

 All 5 Export Received Parts Pin-2 NO GO Answering

5 176-0061 2.7 2.95 3.28
 Wall thickness there is no Drawing Specification
1.4 3.83 1.74
2.3 Target Setting

50
43
40

30

20

10

0
0
Current Target

 Achieve Zero Defect in Pin Collar Deformation.

3. Factor Analysis

CAUSE EFFECT
MAN MACHINE

Chip Accumulation Setup part Handling 5 Variation

NG Part Mix Equalizer Clamping

JH
Clamp pad Handling Capability (OP15) 5
Non Adherence Skill Variation
Fillet Rolling Load
Offset
Training
Reactivity Capability
(OP30) Pin Width Oversize
Wrong Offset
Monitoring Plan
PIN COLLAR
Non Adherence
DEFORMATION
Forging Draft J#2 Equalizer Inefficient(OP15)
Fillet Rolling
J#2 Datum
Variation
Pin Wall thickness Less 1 Centering
PMS disabled

J#2 Centre Linear Shift Design

2 Pin Milling Excess Offset Excess load
No Linear Control
N1 & N3 Management
4 MQA
Overall Shift Monitoring Plan

MATERIAL 3 No Out flow control

METHOD
4.Determination of Countermeasures(Priority )
Validation
No. Brain Storming Point Validation / Observation Attach
Result

Pin Collar Wall Thickness Pin-2 Wall Thickness found less compared with
1 (Design Issue) Pin-1 & Pin-3 Significant - X

OP 15 Milling Linear Jun’16(Some of the Shift ) Milling Linear

2 Dimension Control Deviated below the minimum tolerance
Significant -X

Outflow Prevention No As per POS Only Visual control , No Specific

3 Specific check points Control ( No Gauge information ) Significant - X

Forging Journal #2 Center Raw material validation checked Center position

4 Deviation no Deviation
Insignificant - O

Fillet Rolling Load Parameters confirmed as per

5 Fillet Rolling Load
POS – Found OK
InSignificant - O

6 Setting Part Mix-up Part Handling confirmed in Line – Result OK InSignificant - O

 5 . Implementation of Countermeasures

Sl.
No. What (Activity) Why Who When Where How

Pin Collar Wall To Avoid

1 Thickness deformation Product WK40 Raw Material Die Modification
(Design Issue) after Machining

OP 15 Milling
To Prevent Pin- WK31-
2 Linear Dimension MFG Control Room Control Tolerance
2 Deformation 16
Control

Outflow
To check At Final
Prevention No 100% Check with GO &
3 Deformation in Mfg 15.12.16 Inspection in CS
Specific check NOGO Gauge
Final Part Line
points
6. Result Checking :

10  From Aug’16 N1 Controlled

 Dec 15 th onwards 100% Inspection

1 0 0 0 0 0
0
Dec'16 Jan'17 Feb'17 Mar'17 Apr'17 May'17

 Zero Case After Implementation of 100% check from 15/12/16 Supply Parts
7. Standardization

# Countermeasure Document Resp Target Status

Collar width at Top Side - Only visual Control. POS & Gauge
1 Engg 15.12.16
Gauge not available for Deviation Parameter Implemented

2 Awareness to Operators One Point Lesson Mfg 15.12.16

3 Pin wall thickness Improvement Drawing Product Wk 24 Only Trial

THANK YOU
4.1 Raw material Forging Details

PIN-2

PIN-1 & 3

As per Drawing Die Miss match Considering

0.8mm – After Machining Width 1.4mm only
COD derived only for Lesser wall thickness
4.2 Forging Journal #2 Center Deviation
4.3 Milling Linear Result condition [2 months , 23 shifts N1 data]
N1 Monitoring
BR10 CRANK SHAFT OP 15 Gear end face distance trend chart
Spec: 156.8 ± 0.3 GEAR END FACE DIST

157.2
BEFORE - May & June 2016

157.1

157
Moved to Top
156.9 limit 26/06 A shift
156.8
156.8000

156.7 Corrected 156.6922 156.6920

156.7100

156.6 156.637
156.622
156.5952 156.6020
156.5600 156.5500 156.55
156.5 156.536 156.5300 156.54
156.5199
156.4986
156.471 156.475 156.4800
156.466
156.45
156.4
Op 15 NG Op 15 NG 156.4100 Op 15 NG 156.42
Op 20&30 OK Op 20&30 OK Op 20&30 OK
156.3
11 .5.16 A 11 .5.16 B 12.5.16 B 13.5.16 A 13.5.16B 26.5.16 A 27 .5.16A 28.5.16 A 30 .5.16 A 10.6.16 B 10.6.16 C 11 .6.16B 11 .6.16C 16 .6.16A 16 6.16B 17 .6.16A 17 .6.16B 19.6.16 A 19.6.16 A 19.6.16 B 25 .6.16B 25 .6.16C 26.6.16 A
4.4 Outflow Prevention Status

a Crank PIN #2

RE EQM-.msg

Z2
Y
Only Visual Control at Top side
Z1 during MA Start , No gauge
implement , Not Sufficient
X
 4.4 Fillet Rolling Load

Standard

MC Actual
5.1 BR10 Forging Die Modification schedule

1st Trial plan – WK24 / 17

SOP Plan – WK40 / 17 Microsoft
PowerPoint Presentation
5.2 N1 Control Monitoring
5.3 N1 Control (Final Inspection )
5.3 Pin-2 Width Over size Flown out Countermeasure