QC CIRCLE

TASK STATUS

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 TASK - CUTTING

1.PROFILE NOT MATCHING

2.TAPER CUTTING

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TASK IMPLEMENTATION

1.PROFILE NOT MATCHING

India Metal One Steel Plate Processing Pvt Ltd DOC. NO-IMOP/F/PD/C/01,

Cutting Log REV:00

Operator Name- Shift-
Machine- Date-

Customer
Date S.No Bar code RM size & Grade Part no Quantity Cutting Time Setting Time Balance RM SOP Followed Remarks
Name

Operator will follow

regularly

Operator sign Line Leader sign production manager sign

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2. TAPER CUTTING SOP will follow stringently
Operation start-up
i. Receive cutting plan from shift supervisor.
ii. Refer Cutting Plan and Work result for details.
iii. LPG Gas Cutting Gas (O2) and Water should be opened.
iv. Switch ON the Machine
v. Check for availability of Program.
vi. Select program on to the machine.
vii. Proper Program should be selected.
viii. Proper Nozzle should be selected.
ix. Nozzle condition should be checked.
x. Clean the Nozzle before start the cutting.
xi. Torch square should be checked.
xii. Sheets should be properly loaded.
xiii. A test piece should be cut and its Quality Dimensions, Visual should be checked. Set up approval
xiv. After proper adjustments once the Quality is achieved start the main program.
xv. After piercing process visually check the nozzle condition. If there is any blockage inside the nozzle
hole, clean it and continue the process.
xvi. Gas cutting component and check it with the approved Tem plate / Critical drawing dimensions.
xvii. First Part Approval report to be made and get approval from authorized person
xviii. If accepted, repeat operation for the required quantity as mentioned the first part report.
xix. If rejected do necessary correction and setting.
xx. After completing the part, datas will be feed into the TENSUITE system.(manual log also need to
maintain) 4
 TASK - MACHINING

DIMENSIONAL ISSUE PART NO 284-3232,284-3238

AND AXLE GP

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 TASK IMPLEMENTATION

Gauge provided(GO&NOGO)

1. Boom sub 248-3232

2. Boom sub 284-3238

to arrest the dimensional

Issue.
Rejected , suggested to
do other Task. Since
there is no collective
involvement of People

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 TASK - BENDING

WRONG BEND

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 TASK TAKEN

IN THE FIRST QUALITY CIRCLE PROJECT WE HAVE

TAKEN THE PROJECT ON

WRONG BEND

Development height
variation found.

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 PROPOSED ACTION

COMMON PROGRAME INSTALLED IN EACH MACHINE AND

PROGRAME NAME ALSO IN EASILY IDENTIFY METHOD.

REQUEST LASER MARK ON 1 JOB FOR EACH BATCH FOR

PARTICULAR PARTS.

THE BELOW FORMAT ATTACHED ALONG WITH EACH

DRAWING.TO AVOID CARELESSNESS.

PROPOSED SOLUTION:
CHECKING METHOD EMPLOYEE CODE DATE

FIRST PART INSPECTION

POSITION & PROGRAM

DIMENSIONS 9
 PPE
ECN
WEAR GOGGLES WEAR SHOES

DATE

FIRST PART WEAR GLOVES WEAR HELMET WEAR EAR PLUG

INSPECTION
DAILY ACTIVITIES
DIMENSIONS FOLLOW SAFETY EQUIPMENTS PROPERLY.

BEFORE STARTING WORK, DAILY AUTONOMUS CHECK LIST NEED TO

SOP UPDATE.

CHOOSE APPROPRIATE PUNCH AND DIE AS PER DRAWING

REQUIREMENTS.

TOOL SETTING METHOD PROPER CENTER ALIGNMENT OF PUNCH AND

DIE NEED TO CHECK VISUALLY AND CLAMP TIGHTELY.

ECN
BEFORE STARTING BENDING, FIRST CHECK THE ENTIRE DIMENSION IN

ACTUAL PART USING DEVELOPMENT VIEW.

DATE
AFTER THAT, OIL CHECKING METHOD DONE ON FIRST PART BEFORE

FIRST PART STARTING PRODUCTION.

INSPECTION FIRST PART INSPECTION NEED TO DO ON EVERY NEW SETTING AND

ENTER ALL THE DIMENSIONS IN QUALITY REPORT.

DIMENSIONS ANGLE CHECKING NEED TO DO ON EVERY JOB IN PRODUCTION TIME

ALSO.

SOP DIMENSIONS NEED TO CHECK FOR EVERY 5 NOS.

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SOP AND CHECK POINTS FORMAT

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 TASK - PEB

1.DENT ISSUE DURING SPLICE WELDING.

2.BASE PLATE DISTROTION.

3. PART MARK IDENTIFY.

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 TASK IMPLEMENTATION

TASK 1.DENT ISSUE DURING SPLICE WELDING

Rejected due to it has

given as KAIZEN
Proposal
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TASK 2 : BASE PLATE DISTORTION

Rejected due to it has MODIFICATION

given as KAIZEN REQUIRED and NOT IN
Proposal PRACTICE NOW
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 PART MARK IDENTIFY

No of Part Mark repeated

No of Qty of Job also incerased

Solution:

Whenever Job completed, Log book updated.

Extra Qty and Part No repeating avoided.

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 TASK SHOTBLASTING & PAINTING

1.SHOTS UNCLEANED

2.PAINTING THICKNESS

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 TASK IMPLEMENTATION

1.SHOTS UNCLEANED

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2.PAINTING THICKNESS PROBLEM
WORK INSTRUCTION FOR PAITING
DOC NO: IMOP/WI/QC/04 REV NO: 00
PURPOSE:

To establish work instruction and stand board this instructions as hand holding assistance for operators.

SCOPE: For Painting

RESPONSIBILITY:
Line leader paint shop
Operator

CUSTOMER: Koyama
PAINT: Primer grey colour
COATING THICKNESS: 60 - 80 microns

SAFETY PRECAUTIONS:
Do not store the paint materials near to the panel board
Operator must wear shoes,goggles,mask,gloves and ear plug
In case of any problem on spary gun contact euipment maintenance department immediately
Follow the preventive maintenance without fail

PPE's:
Safety Mask
Gloves
Safety shoes
Goggles
Helmet
Coverall

MATERIAL NEEDED:
Paint
Thinner

EQUIPMENT NEEDED:
Paint spary gun
Paint booth

PAINTING METHOD:
S.NO DESCRIPTION PICTORIAL VIEW

a)Stirr well before going to use

b) Mix the paint and thinner as per the required ratio.the thinner
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will be added as per the required viscosity (19-21 seconds) and
monitor in the record note.

a) Verify the viscosity rate by using ford cup B4.

b) At the time of painting ensure that the part is,free from
oil,greese,shots and dirty.
2
c) During paiting dont handle the part by using dirty golves.
d)If the receiving part is found to be oily and dust,it should be
wipe it off by using thinner

a)After applying the paint on the part, check the surface is free
from poor coverage,paint randown,uneven coating and peel off.
3 b) Once the painting operation has been completed,1no need to
cross check for coating thickness and it should be monitor in the
record note.

MAINTENANCE:
Preventive Maintenance-
Monthly scheduled maintenance with approval from Head-Production

Breakdown Maintenance-
Breakdown maintenance slip will be issued to maintenance department.After trouble shooting the action taken will be updated in the maintenance
slip with authorization from production

PREPARED BY: APPROVED BY: 18

 TASK STICK & LIFTARM

1.Stick bore 55.25.05 after welding pin not enter

2.Lift arm bore 60.2370.046 & 40.2350.046 pin not
enter
3.Weld under cut - lift arm per assy 6 no

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 TASK NO -1

Stick bore 55.25.05 after

welding pin not enter

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Inline correction by
Hammering method

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 Arresting Pin will be
provided at welding
manipulator to avoid
welding distortion, Thus
the inline issue will be
getting solved

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 TASK NO -2

Lift arm bore 60.2370.046 &

40.2350.046 pin not
Enter

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 DIA 40.2350.046- PIN OK
Shim addition and shim
adjustment in Welding
manipulator. Inline Pin
found OK

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 DIA 60.2370.046- PIN NOT OK
Shim addition and shim
adjustment in Welding
manipulator- Trail is
going on

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 TASK NO -3

Weld under cut - lift arm per

assembly 6 no

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Welding is carried out in
sitting Position some
movement is difficult in
this condition

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Welding is carried out in
standing Position Free
movement is possible

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 TASK MAINFRAME & BOOM

1. Weld porosity more in 9R9916 ,9R9917 tube

with 20 Thick plate welding
2. Weld porosity & undercut in Rail mount inside
area welding
3. Boom 284-3232 Sub assy outer side face
grinding done after welding Gap gauge
answering
4. Boom - Dimension variation in 4 boss fitup

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 This proposal rejected
since there is no
involvement of people. It
is design issue

Tower As Lift cylinder Pad ( 127-9449)

with Tube (111-9788) welding Crack

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 TASK 1 - IMPLEMENTATION
Implementation of spacer gauge in the
fit-up locator to avoid inside dimension
variation in 1836268 Boss

Inside pitch dim 1523 and

perpendicularity were maintaining

Spacer gauge added on

both ends which locate
the boss perpendicular
to meet inside pitch

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 TASK 2 - IMPLEMENTATION
Welding distortion happen on sub1 side during welding
Inline pin not answering
Width increased Gap gauge not answering

By making through pin entering both bores with tightening

thread clamp can control weld distortion

Implementation in progress Not

Completed

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THANK YOU

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