WEEKLY CLD MEET

APRIL 2022- WEEK 4

 Week wise Rejection % graph
Fdy Rej % M/C shop Rej % Total % Target
14.00% CR22- 4.342 T
3DU- 2.406T
NO601- 804kg
11.84% Spindle714- 575kg
12.00%
Spindle 714-1.3 T
Half sheave-2.74
10.00% 9.39% T 9.40%
CR 22- 0.938 T 8.51%
7.72%
8.00% 7.22%
6.86%

6.00% 5.58% 5.65%

4.98% 4.74%
4.78%
4.15%
4.00% 3.81% 3.75% 3.78%
2.94% 3.07%

2.00%

0.00%
Mar-22 Apr-W1 Apr-W2 Apr-W3 Apr-W4 Apr-22
(01 to 05) (06 to 12) (13 to 19) (20 to 26)
 Customer Complaints
Internal End
1. Old Side Hsg- Fett not
5 1. CR22- Open ok
Grain Structure 2. CR 22- CAst patch
2. Oil Pan-Leakage @bore due to excess fet-
1. Nord small & Big- 3. Spindle714- sand 4 tling
4 Improper S/F finish fusion & Veining 1.Hsg 2001- Extra 3. Hsg 2001-Shri @ bore
2. Old Side Hsg- Sand Material 4. Piston 902425- Shrink-
fusion 2. Old Side Hsg- Ex age @ bore area
3 Fett
3

Class Hsg 1001-

2 Excess Fettling 2 TG Case302-
2
Sand in pipe

1 1
1

0 0
0
Apr-W1 Apr-W2 Apr-W3 Apr-W4
(01 to 05) (06 to 12) (13 to 19) (20 to 26)
 Top 10 Production Parts of Mar-22 & Their status in Apr-22

Mar-22 % Rejection Status Apr-22 % Rejection Status

Sr. No. Part Name Apr-W1 Apr-W2 Apr-W3 Apr-W4 Apr

Target Actual Fdy Stage M/C stage Target
01 to 05 06 to 12 13 to 19 20 to 26 Overall

1 3DU 30 30.80% 15.74% 15.06% 11 12.81 5.92 50.32 10.08 13.16

2 CR 22 BODY 4 4.52% 2.66% 1.86% 4 13.84 11.67 3.47 10.40 8.96

3 875 CARRIER 20 180.15% 43.38% 136.76% 11 - 4.88 - 14.58 21.17

4 SPINDLE 714 4.5 9.05% 2.83% 6.22% 4.5 4.60 10.31 2.09 19.82 7.79

5 DIPL COVER 2.5 3.05% 1.13% 1.91% 2.5 1.58 2.21 4.35 41.67 3.47

6 OIL PAN 4.92% 3.05% 1.87% 4 2.75 1.53 2.18 2.03 2.04

7 TG CASE 302 8 10.53% 6.25% 4.28% 8 1.85 19.44 8.21 9.77 7.32

8 Bracket 820 LH 13.05% 3.61% 9.44% 8 - 1.18 6.06 - 10.08

9 PADMINI 147200100 28.81% 3.00% 25.81% 15 - - - - -

10 SIDE HOUSING LH 8006 18.56% 1.44% 17.12% 8 - 9.13 3.00 1.97 8.11
 Top 10 production parts by total rejection (weight)
PART PRODUCTION TOTAL REJ Fdy stage M/C stage
SN PART NAME
WT.
Defects (Qty)
QTY WT QTY WT % QTY WT % QTY WT %

Slag (1165), BH (296),

1 CR 22 BODY 6.795 24570 166.95 2201 14.96 8.96 848 5.76 3.45 1353 9.19 5.51
Fett Issues (231), SD (153)

Core lift/shift (531), Slag (485),

2 3DU 5.336 15912 84.91 1991 10.62 12.51 777 4.15 4.88 1214 6.48 7.63
Cavity not Ok(140), Core Defect(220)

Short pour(62), Shrinkage (48),

3 SPINDLE 714 21.304 2182 46.49 170 3.62 7.79 86 1.83 3.94 84 1.79 3.85
BH (19), Slag(15), Sand Drop (12)

4 TG CASE 302 18.777 1339 25.14 98 1.84 7.32 55 1.03 4.11 43 0.81 3.21 BH (21), Core shift(14),
Leakage (13), Slag(11), Fett issue (9)

Slag (27), Sand drop (6),

5 housing NO601 27.735 538 14.92 53 1.47 9.85 11 0.31 2.04 42 1.16 7.81 Shri (5), Short pour (4)

FLANGE DIFF CARRIER Shri (30), BH (16), Slag (15),

6 FORK-9897 17.23 290 5.00 81 1.40 27.93 8 0.14 2.76 73 1.26 25.17 Fett Issues (10)

Scabbing (21), K/O damage (13),

7 OIL PAN 22.013 2988 65.77 61 1.34 2.04 55 1.21 1.84 6 0.13 0.20
Slag (9)

8 DIPL COVER 17.928 2046 36.68 71 1.27 3.47 31 0.56 1.52 40 0.72 1.96 Slag (21), BH (17), Excess S/B(15)

9 STEERING HUB 2667 19.07 78 1.49 60 1.14 76.92 19 0.36 24.36 41 0.78 52.56 Slag (24), BH (7), SHri (5)

Hard issue old castings (93),

10 JD COVER 344 8.563 1956 16.75 110 0.94 5.62 105 0.90 5.37 5 0.04 0.26
Fett issue (7)
 Action Plan

Part Defective Defect Root cause Current Rejection % targeted

Defect Action Taken Effectiveness
Name qty contribution analysis rejection % in month April 2022
CR 22 Proper deslaging process
Slag 1165 52.93% Liquid slag 4.00 % 8.96%
body defined

Damage 231 10.49% Negligence Monitor stage wise damage Result in 4rd week 4.00 % 8.96%

SPINDLE Proper deslaging process Two heats verified and found

714 Short pour 62 36.47 % Liquid slag 4.5 % 7.79%
defined. OK. (80 nos)

DIPL Last four days no issue

Excess S/B 15 21.12 % Hanger wear out Stand by hanger to be made. 2.5 % 3.47 %
Cover arises.

Slag observed in Trial

NO 601 Slag 27 50.94% Trial planed . 2.00% 9.85 %
batch

Rectangular Chill should be

Hsg2001 Shrinkage 79 68.10 % Movement of chill Trial planed on 29/4/22
used .
 BUNCH WT CHANGE REPORT

No. Part Name Old bunch wt New Bunch wt Remark

1
Bracket 363 50.21 51.17 No change

2 Carrier 513 36.8 37.74 In gate size changed

3 Case King 137 40 44.33 Development part

 Incoming Raw material rejected /Deviations
BORING LOT REJECTION

Sr. No. DATE Material SUPPLIER NAME FINE 15 % max FINE 8 % MAX sand fine Remark
(600 Micron) (425 Micron) 0.5 % max

1 19.04.2022 CI boring S.M. STEELS 15.07% 8.40% - REJECT

2 22.04.2022 CI boring S.M. STEELS - 8.69% - REJECT
3 22.04.2022 CI boring S.M. STEELS 10.16% 4.97% 1.55% REJECT

4 26.04.2022 CI boring S.M. STEELS - 8.69% - REJECT

RAW MATERIAL REJECT

Sr. No. DATE Material SUPPLIER NAME OBSERVATION Remark

1 21.04.2022 CRCA SCARP JINIT STEEL High Cr%0.058% required Cr 0.02% Max reject

2 22.04.2022 CRCA SCARP SMAA STEEL HIgh Mn %0.512% required Mn 0.35% Max reject

3 23.04.2022 CRCA SCARP MUNGIPA CO HIgh Mn %0.458% required Mn 0.35% Max reject

under Deviation
4 23.04.2022 S.G PIG IRON BHOMI ASSOCIATES Low silicon %0.835 required Silicon 1.25 to 3.0%
accepted