CYLINDER BLOCK (BR10HS) SEALING

PLUG CAMEOUT
(BRAZIL & BURSA PLANT)

PWT | 27 Mar 2017

 8.Conclusion Review & future action

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

PWT | 27 Mar 2017

1.Problem Description
Concern :
Oil Pressure Drop in Vehicle During Testing & Found Sealing Plug Dia12 Came out from Cylinder Block
Concern Reported Date & Qty. :
Customer 28Mar 30Mar 7 Apr 3 May Remarks
Brazil 1 2 At Vehicle
Bursa 1 6 Plant
- Concern Reported from Brazil & Bursa and Started Sorting the WP Depth by caliper

Sorting Status
Customer Apr May Remarks

Brazil 150 1 Before Cutoff Old Machine Parts in Apr

After Cutoff New Machine Parts in May
Bursa 661 After Cutoff New Machine Parts in May

- Bursa Case Recheck to be done by FP Gauge Requested by RNAIPL

- Gauge Sent on WK22 to Bursa

PWT | 27 Mar 2017

2.Grasping Current Condition
1. Rejection Status – Sealing Plug came off

4
7
3

2
3
1

0
Brazil Bursa

Brazil

PWT | 27 Mar 2017

2.1 Target Setting

12
10

No of Leak Defect
10

2
0
0
Vehicle Target

PWT | 27 Mar 2017

3. Factor Analysis

CAUSE EFFECT
MAN MACHINE

Lack of Knowledge
Training High Variation 3
Low
Non Conformity Skill Air Pressure
Wear Out
Reactivity
Life Monitoring
Monitoring Plan
Pressing Tool
Non Adherence
6 Tool Depth WELCH
PLUG CAME

Low Hardness OUT

4 Diameter Control on Tool Full Butting
2
Oversize
Hardness 1
Hole Dimension Gun Position Control Guiding on Both Axis
Diameter
5
Undersize Guiding Mechanism
Plug Dimension

MATERIAL METHOD

PWT | 27 Mar 2017

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

Plug Pressing Process Guide Lack of Guiding Mechanism to control the

1 Control Pressing Gun
Significant - X

Gun Position Control – Tool Potential chance of Pressing tool not reach to end
2 Full Butting till end. position observed during negative validation
Significant - X

Pneumatic Gun Air Pressure

3 Variation
Air Pressure Control Available, Alarm if Low/High Insignificant -- O

Hole Diameter n30 process capability Study done

4 Hole Diameter Oversize
found OK
Insignificant -- O

5 Plug Diameter undersize Plug Diameter n10 Checked Found OK Insignificant -- O

Parts found in minimum side spec , potential

6 Tool Depth
chance less depth
Significant - X

PWT | 27 Mar 2017

 SIGNIFICANT

Cylinder Block – Plug Pressing Gun Guide Mechanism

Plug Seal Pressed without support Guide

Lack of Guiding Mechanism to control the Pressing Gun, Potential chance for depth variation

PWT | 27 Mar 2017

 SIGNIFICANT

Cylinder Block – Plug Pressing Gun Position Control

Only Manual Control on Tool Position Reach Till End

Possible of Depth Variation if Triggering done incomplete

Potential chance of Pressing tool not reach to end position observed during negative validation

PWT | 27 Mar 2017

 INSIGNIFICANT

Cylinder Block – Plug Pressing Pneumatic Air Control

Ø12mm Plug is Pressed with Pneumatic Gun

Pressure : 4~6 Kg/cm2 Actual :5.5Kg/Cm2

Air Pressure Control Available, Alarm generate if Low/High

PWT | 27 Mar 2017

 INSIGNIFICANT

Cylinder Block – Hole Diameter

Hole Diameter – Capability Found OK

PWT | 27 Mar 2017

 INSIGNIFICANT

Welch Plug Diameter

Welch Plug Diameter – Found OK

PWT | 27 Mar 2017

 SIGNIFICANT

Cylinder Block – Plug Pressing Tool Depth

Welch Plug Depth - Hole 6071 - March

2.75

2.5

2.25

1.75

1.5

1.25
1 2 3 4 5 6 7 8 9 1011121314151617181920212223242526272829303132333435363738394041424344454647484950

USL Nominal LSL Loc#1 Loc#2 Loc#3 Loc#4

Plug Depth Maintained in Minimum side , potential risk for less depth

PWT | 27 Mar 2017

5 . Implementation of Countermeasures

Sl. What (Activity) Why Who When Where How

No.

To avoid depth
Plug Pressing Process OP190 Plug Pressing New Pressing Station with Proper
1 Variation & Improper Engg WK01
Guide Control Operation Guiding mechanism on X&Y Axis
Pressing

To Maintain depth in
Plug Pressing Tool Depth OP190 Plug pressing
2 safer condition Mfg WK13 Grinding the Tool Butting Surface
to be reworked Tool
nominal & above

To Avoid Incomplete
Gun Position Control – OP190 Plug Pressing Plan to Provide Sensor feedback to
3 Pressing & Less Engg WK31
Tool Full Butting till end. Operation ensure Tool Butting till end.
Depth

PWT | 27 Mar 2017

5 . Countermeasure-1
Before (Till Dec’2016) After (w.e.f – January 1st 2017)

Plug Seal Pressed without support Guide

Plug Seal Pressed with support of Guide Pin

 Plug Pressing process Facilitated with new machine for 300K Production ramp up Since January 2017
PWT | 27 Mar 2017
6 . Result Checking

Current condition

Plug Pressing Depth – n30 Capability Check done found OK

PWT | 27 Mar 2017

 7 . Standardization
# Countermeasure Document Resp Target Status
New Pressing Station with Proper Guiding
1 Facility Improved Engg WK01/17 Completed
mechanism on X&Y Axis

Plug Pressing Tool reworked and maintain in

2 Tool drawing Engg WK13 Completed
nominal and above

3 Sensor feedback to ensure Tool Butting till end MQA Engg WK31/17 Pending

Temporary Countermeasure :

100% Gauge Confirmation at Firewall Inspection , Check Item Added in Check Sheet

PWT | 27 Mar 2017