NCR_Number NCR_Title NCR_Coordinator Asignee2D3D

I31162 1031319 Welding Underfill Arun Kumar Arun Kumar

I33321 Attachment Plate Welding Issue Arun Kumar Mesias Baskaran
I34482 Welding Inconsistency Arun Kumar Mesias Baskaran
Asignee4D5D6D Asignee7D8D BusinessUnit Category Classification
Arun Kumar Mesias Baskaran New Sales Error 1. Safety
Mesias Baskaran Mesias Baskaran New Sales Error 2. Quality
Mesias Baskaran Mesias Baskaran Error 1. Safety
ErrorCode FacilityWhereDetected Function ID
05 - Welding (special process acc IRIS) Dellner India - DCIN Procurement 1173
05 - Welding (special process acc IRIS) Dellner India - DCIN Procurement 3368
05 - Welding (special process acc IRIS) Dellner India - DCIN Procurement 4566
NCR_2D NCR_3D
Inspected all the parts in Stores and found 10Pcs with the Parts being corrected at local En15085 supplier (Airflow)
All availabel Parts 57nos Quranined , All 57nos Suspected Parts are send back to Supplier for Welding
All available Parts are Qurantined for re-work , Qurantined Parts are send back to welding supplier for welding r
NCR_4D NCR_5D
Due to the manual rotate & the welded of Square tube each fae•manaual
i rotation
Work and welding
Instruction for the start from end
manipulator corner
is not of the square tube
in place.
Not checked after welding . IMPROPER
• FUSION
Production AND
weld LESS not
coupon DEPOSITION
prepared asONper
SQUARE BLOCK
ISO 15613
• EDGE PREPARATION
Welding Notmostly
carried out done .in extended shifts during the nights where welders are oversta
During inspection it was missed .
• Welder not controlled multiple layer in the groove by proper sequence
• Dellner India from sub supplier information Provided wrong information (typo error) that
Implement the edge preparation on square block.
1.Assosiate
NCR_6D
Implemented hasmultiple
been trained and&made
weld run aware
multiple of all instead
process Points to
of be before
single run.packing .
2.All
Root welded
run will corner are merged
be covered by GTAW . process
•3.Indruduced
Final weld runthe
Manipulatorwillrotation
RPM andtype
be done speed
by of welding
GMAW control fixture and is
information
process. around
addedthe Square
in Work tube . & placed near the welding zone. Provided training to welder for following the
instruction
4. welding
•Load test Vstart
Half will befrom
and Half
doneYcentre of tube
production
on Initial instead
weld
2 sample is to of corner
carried . per ISO 15613 to meet the requirement of EN 15085-4
out the
analyse as
• weld Trained welder is used for Multiple layer welding. Will implement Macro check every 6 months
strength.
•Implementation
New WPS is prepared
Target date as per EN15614 & WPQR as per EN9606-1 to test the Raw material E470. Weld consumable used is ER80 SG
: 25.11.2017
Added chamfer 45⁰x5 on square block.
First weld run is covered by GTAW process.
NCR_7D
Final weld run is completed by GMAW process.
After welding
All welded verified
parts the actual
are 100% throatdone
inspection thickness
as perwith weld ,gauge.
EN5817 class -c
Evaluated the surface defect by liquid penetrant test.
Load test carried out on actual component.
All
Loadtheapplied
parts are
loadvisually
>169 KNchecked andton)
(Apx 17 found satisfactory
without fracture.(Refer attached report No-RE/2017/11/0369)
Negative Validation
Actual regular Part has failed at 96.070 KN (Refer attached report No-RE/2017/11/0381)
NCR_8D NCR_ClosingDate NCR_CreatedDate
Before packing all parts are checked 2017-07-14 2017-01-03
Negative validation done and ok . 2017-11-27 2017-11-27
All the key points concentrated and display the work 2018-06-06 2018-05-04
NCR_IssueDescription NCR_LastModifiedDate NCR_Qty
Welding underfill in corner area. 2017-07-14 10
Faste Attachment Weld Aeebly weld Broken . 2017-11-27 1
Uneven Weld Bead. Excess Reinforcements affecting visual appearance.
2018-06-06 16
Wrong Filler wire chosen for welding
NCR_ReportedBy NCR_VerificationComment
Suresh Kumar verified ok .
verified found ok .
Mesias
Arun Kumar Documents and visual veriried du
State Subsidiary First7D_8D
Closed NCRs Dellner India - DCIN 2017-07-14
Closed NCRs Dellner India - DCIN 2017-11-27
Closed NCRs Dellner India - DCIN 2018-06-06