Action Plan for Quality Issues with M/S Sangkaj Bright Wires Pvt Ltd

ACTION PLAN FOR QUALITY ISSUE Supplier Name: M/S SANGKAJ BRIGHT WIRES PVT LTD Date: 24th April -2024

DEFECT PHENOMENA DETAILS Phenomenon: M26X1-6H Threading No-Go Tight. Supplier: Sangkaj Bright Wires Pvt. Ltd. Model: HMS-30 & HMP-30 Parts No.: 550FA19033 Parts name: Fork Pipe Date of Occurrence: 24/04/2024 Ok Parts NG Parts Spec- M26X1-6h Observed- M26X1-6h Tight Parts Stock check results Area ETPL End SBWPL End Total Stock 15500 4900 Checked 15500 4900 NG 11 02 Status Completed Completed

ACTION PLAN FOR : M26X1-6H Threading No - Go Tight. Part Name: Fork Pipe ( HMS30 & HMP30 ) Type Of Phenomena If Repeated No. Of Occurrence Process Flow: Problem Phenomenon : New/Repeated New 00- Receipt Of material 01 - Inward Inspection 02 - CNC 1sT Setup 03 - CNC 2ND Setup 04 - Drilling 05 - Final Inspection. 06 - Anti Rust Oil Application. 07 - Air Cleaning. 08 - Dispatch Total Qty. Ok Qty. NG Qty. 20400 20387 13 Cause Verification & Fact Analysis: Parameter Specification Act. Observation Jud. Man Method Threading M26X1-6h M26X1-6h Tight Not ok New operator Insert Change WI Problem Analysis: M26X1-6H Threading No-Go Tight. Why-1 Why-2 Why-3 Why-4 Wrong offset given by operator s. Why-5 At The Time of correction operator taken 0.3mm Offset instead of 0.03mm. Wear Offset Lock Material Hardness More M26X1-6H Threading No-Go Tight M26X1-6H Threading No-Go Tight Inspection Threading Minor Diameter was at Higher Side. Wear offset not lock in CNC machine. Occurrence Side M/c Material Inspection Done On Sampling Basis. (5 Nos / Lot) Sr. No Posibilities Causes Verification Result skipped by Operator and line Inspector 1 New Operator Skilled Operator O Insert Change WI Not Available Detection Side C Measure:- 1.Wear Offset Not Lock In CNC Machine. 2. Inspection Done On Sampling Basis ( 5 Nos / Lot). 2 Insert Change WI X Wear Offset Not Lock In Cnc Machine. Material Hardness Ok. 3 Wear Offset Lock X Detection Side Countermeasure Wear Offset locked By 0.03mm In CNC Machine. Occurrence side countermeasure At Final Inspection stage we have started the 100% inspection at with the help of thread plug gauge Material Hardness More 4 O Conclusion:

OCCURRENCE SIDE ACTION BEFORE AFTER Wear Offset Not Lock In CNC Machine. Wear Offset locked By 0.03mm In CNC Machine.

OCCURRENCE SIDE ACTION BEFORE AFTER Tool Life Not Decided & Lock In CNC Machine. Too life decided & Lock in CNC Machine.

INSPECTION SIDE ACTION BEFORE AFTER Sangkaj Bright Wires Pvt. Ltd. CONTROL PLAN Sangkaj Bright Wires Pvt. Ltd. CONTROL PLAN Endurance Tech. Ltd. Format No:SBWPL/CP/550FA19033-00 Endurance Tech. Ltd. Format No:SBWPL/CP/550FA19033-00 Protype Production Pre launch Date(Orig):-07.12.2019 Protype Production Key contact /Phone:- Mr.Shivpal Singh.,8690443411 Pre launch Date(Orig):-07.12.2019 Page -01 of 02 Key contact /Phone:- Mr.Shivpal Singh.,8690443411 Page -01 of 02 FP-01/9033 FP-01/9033 Core Team:- Mr. Amol Rathod Mr.Bijay Maity Control Plan Number :- Customer Engineering Approval /Date (If Reqd.)_______ Core Team:- Mr. Amol Rathod Mr.Bijay Maity Control Plan Number :- Customer Engineering Approval /Date (If Reqd.)_______ 550FA19033 Rev:- XD 27.02.2015 Supplier / Plant Approval /Date :-_______________________ Customer Quality Approval/Date(if Reqd.)____________ 550FA19033 Rev:- XD 27.02.2015 Supplier / Plant Approval /Date :-_______________________ Customer Quality Approval/Date(if Reqd.)____________ Part NuMber / latest Change Lavel:- Part NuMber / latest Change Lavel:- Part Name / Description:- FORK PIPE HMS-30 & HMP-30 Other Approval / Date(if reqd):-________________________ Other Approval/Date(If Reqd.)_____________________ Part Name / Description:- FORK PIPE HMS-30 & HMP-30 Other Approval / Date(if reqd):-________________________ Other Approval/Date(If Reqd.)_____________________ Sangkaj Bright Wires Pvt. Ltd, 713/1 ,HALOL Sangkaj Bright Wires Pvt. Ltd, 713/1 ,HALOL Supplier/Plant:- Supplier code:- 101186 Customer Name:- Endurance Tech. Ltd. SYMBOLS FOR PERSON INCHARGE Supplier/Plant:- Supplier code:- 101186 Customer Name:- Endurance Tech. Ltd. SYMBOLS FOR PERSON INCHARGE OPERATOR INSPECTOR ENGINEER OPERATOR INSPECTOR ENGINEER MFG MFG QC/QA QC/QA Machine Device,Jig.Tool s For Mfg. Special Char./ Class Machine Device,Jig.Tool s For Mfg. Special Char./ Class Process Name/ Operation Discription Process Name/ Operation Discription Characteristic Part/Process No. Methods Characteristic Part/Process No. Methods Product /Process Specificaton/Tolera nce Evaluaton Measurment Technique Tool Change Freq. Sample Product /Process Specificaton/Tolera nce Evaluaton Measurment Technique Tool Change Freq. Sample Poka Yoke Corective Action Plan Responsibil ty Poka Yoke Corective Action Plan Product Process Control Method Reaction Plan Responsibil ty Sr.No. Product Process Control Method Reaction Plan Sr.No. Size Freq. Size Freq. If facing found Under size or over Size stop the machine, inform to If angle found less or more stop m/c, inform to supervisor If angle found less or more stop m/c, inform to supervisor If Dia found less or more stop m/c, inform to supervisor If Dia found less or more stop m/c, inform to supervisor If Distance found less or more stop m/c, inform to supervisor If Distance found less or more stop m/c, inform to supervisor If Distance found less or more stop m/c, inform to supervisor If concentricity found more stop the m/c inform to Supervosor If angle found less or more stop m/c, inform to supervisor If angle found less or more stop m/c, inform to supervisor In process Inspection Record If facing found Under size or over Size stop the machine, inform to If angle found less or more stop m/c, inform to supervisor If angle found less or more stop m/c, inform to supervisor If Dia found less or more stop m/c, inform to supervisor If Dia found less or more stop m/c, inform to supervisor If Distance found less or more stop m/c, inform to supervisor If Distance found less or more stop m/c, inform to supervisor If Distance found less or more stop m/c, inform to supervisor If concentricity found more stop the m/c inform to Supervosor If angle found less or more stop m/c, inform to supervisor If angle found less or more stop m/c, inform to supervisor 100% 020 CNC Turning-I st Diameter 26.30+0.1 CNC Machine 1 - - Plug gauge - - Inspector change insert In process Inspection Record 100% 020 CNC Turning-I st Diameter 26.30+0.1 CNC Machine 1 - - Plug gauge - - Inspector change insert Chamfer Angle In process Inspection Record QA At the time of setting 1.5 2 - - Profile Projector - - Take offset properly Chamfer Angle In process Inspection Record QA Engineer At the time of setting 1.5 2 - - Profile Projector - - Take offset properly Engineer Chamfer Distance In process Inspection Record QA At the time of setting 14 3 - - Profile Projector - - Take offset properly Chamfer Distance In process Inspection Record QA Engineer At the time of setting 14 3 - - Profile Projector - - Take offset properly Engineer Wear Offset locked By 0.03mm In CNC Machine. Threading Minor Dia. In process Inspection Record Operator & Inspector 100% & 5 Nos / Hour 4 - - 25.08+0.04 Plug Gauge - Take offset properly 1 st of approval& 5 Nos/Hour In process Inspection Record Minor Dia. 4 - - 25.08+0.04 Plug gauge - - Inspector Take offset properly In process Inspection Record Operator & Inspector Offest Lock Provided 100% & 5 Nos / Hour Threading 5 - - M26X1- 6h TPG. - In process Inspection Record Offest Lock Provided 100% Threading 5 - - M26x1- 6h TPG. - - Inspector Threeding Depth 1 st of approval& 5 Nos/Hour In process Inspection Record 6 - - 22.00+1.0 DVC - - Inspector Take offset properly Threeding Depth 1 st of approval& 5 Nos/Hour In process Inspection Record 6 - - 22.00+1.0 DVC - - Inspector Take offset properly Counter Depth In process Inspection Record 100% 7 - - 9.5 0.2 DVC - - Inspector Take offset properly Counter Depth In process Inspection Record 100% 7 - - 9.5 0.2 DVC - - Inspector Take offset properly 1 st of approval & 5 Nos/Hour In process Inspection Record Depth 8 - - 26 DVC - - Inspector Take offset properly 1 st of approval & 5 Nos/Hour In process Inspection Record Depth 8 - - 26 DVC - - Inspector Take offset properly 1 st of approval& 5 Nos/Hour 0.1 B 9 - - Sp.Gauge - - - Operator correct the chamfer Concentricity 1 st of approval& 5 Nos/Hour 0.1 B 9 - - Sp.Gauge - - - Operator correct the chamfer Concentricity In process Inspection Record QA At the time of setting Chamfer 1.5X30 10 - - Profile Projector - - Take offset properly Engineer In process Inspection Record QA At the time of setting Chamfer 1.5X30 10 - - Profile Projector - - Take offset properly Engineer In process Inspection Record QA At the time of setting Chamfer 1X30 11 - - Profile Projector - - Take offset properly Engineer In process Inspection Record QA At the time of setting Chamfer 1X30 11 - - Profile Projector - - Take offset properly Note:- Engineer 1 2 3 4 5 6 Special characteristic to be denoted by this symbol Note:- indicated as record of above variables in first piece & Last piece report before mould unloading for 5 Nos. 1 2 3 4 5 6 Special characteristic to be denoted by this symbol indicated as record of above variables in first piece & Last piece report before mould unloading for 5 Nos. For Variables type of special characteristic control method should be (X - R chart). Lay out Inspection - all dimensions specificed in the drawing will be checked. Inprocess Inspection is termed as stage product audit. Product Audit / Process Audit to be conduct as per plan. For Variables type of special characteristic control method should be (X - R chart). Lay out Inspection - all dimensions specificed in the drawing will be checked. Inprocess Inspection is termed as stage product audit. Product Audit / Process Audit to be conduct as per plan. Revision No. Date Change Mr. Amol Rathod Mr. Shivpal Singh Shiv Pal Singh Date Revision No. Change Wear Offest Lock Provided By 0.03mm & Inspection Frequency Of Minor Diameter Increase by 100% . Mr. Amol Rathod Mr. Shivpal Singh Shiv Pal Singh 1 25.04.24 Approved By PREPARED BY APPROVED BY Approved By PREPARED BY APPROVED BY Threading Minor Diameter to be checking on Hourly Basis As 5 Nos/Hours. Threading Minor Diameter checking frequency to be change 100% by operator & 5 Nos / Hours Inspector.

INSPECTION SIDE ACTION BEFORE AFTER FAILURE MODE AND EFFECT ANALYSIS ( PROCESS FMEA ) Process Responsibility:- Mr. Shivpal Singh FAILURE MODE AND EFFECT ANALYSIS ( PROCESS FMEA ) Process Responsibility:- Mr. Shivpal Singh Item.: Fork Pipe FMEA No.:.SBWPL/PFMEA/550FACH024-00 Item.: Fork Pipe FMEA No.:.SBWPL/PFMEA/550FACH024-00 Key date : REV No.: 00 Page 0 of 0 Drag No.:550FA19033 Part Name.:HMS-30 & HMP-30 Rev No.: XD Key date : REV No.: 00 Page 0 of 0 Drag No.:550FA19033 Rev No.: XD Core Team : Mr. Amol Rathod, Mr. Bijay Maity Core Team : Mr. Amol Rathod, Mr. Bijay Maity Origin Date: Part Name.:HMS-30 & HMP-30 Customer Name :- Endurance Technology Ltd. Rev. Date: 07.12.2019 Origin Date: Supplier Name :- Sangkaj Bright Wires Pvt. Ltd. Customer Name :- Endurance Technology Ltd. Rev. Date: 07.12.2019 ACTION RESULTS Process Function/Req uirement Potential Cause's)/ Mechanism's) of Failure Current Process Controls Detection R P N Recomme nded (Action's) Supplier Name :- Sangkaj Bright Wires Pvt. Ltd. Process No. Potential' Failure Mode Potential Effect's) of Failure SEV . CLA SS OC C. Current Process Controls Prevention DETECT ION Respons ibility Action Taken OCC DET SEV R P N ACTION RESULTS Process Function/Req uirement Potential Cause's)/ Mechanism's) of Failure Current Process Controls Detection R P N Recomme nded (Action's) Process No. Potential' Failure Mode Potential Effect's) of Failure SEV . CLA SS OC C. Current Process Controls Prevention DETECT ION Respons ibility Action Taken OCC DET SEV R P N 1) Wear Offset locked By 0.03mm In CNC Machine. 2) 100% inspection of threading minor diameter with the help of plug gauge. 3) Insert Change & Plug Gauge inspection work instruction display on shop flower. 1.Wrong Selection of Threading insert 2.job not clamped properly. 3.Insert 1.Wrong programing provide fot threading operation. 1.Work Instruction displayed for proper selection of Insert & Proper clamping of job 1. Component may not fit (loos fit) with main assembly. 100% inspection after threading. 7 4 4 112 1.Wrong Selection of Threading insert 2.job not clamped properly. 3.Insert Wear Out 1.Work Instruction displayed for proper selection of Insert & Proper clamping of job Mr. Shivpal Singh Thread cutting sample pitch check on Profile projector. 1. Component may not fit (loos fit) with main assembly. 100% inspection after threading. 7 4 4 112 25.04.2024 7 4 3 84 1.Work Instruction displayed for proper selection of Drill Bit. Pitch not Maintain 6 3 5 90 Threading M26x1-6H Defect 1.Insert not maitained the thread perpendicular with job 2.job not clamped properly. 1.Work Instruction displayed for proper clamping . Perpendicularity checked by Height gauge and dial gauge. Threading M26x1-6H Defect Taper Threading 6 3 5 90 Freeze the offset and Insert changing frequency setting and display the Inprocess check sheet and tool life chart on machine. Improper offset provide in program and Insert wear out. 100% Inspection I.D. by Plain plug gauge Threding Length undersize 5 4 4 80 1.Wrong programing provide fot threading operation. Thread cutting sample pitch check on Profile projector. 1.Work Instruction displayed for proper selection of Drill Bit. Pitch not Maintain 6 3 5 90 1.Insert not maitained the thread perpendicular with job 2.job not clamped properly. ID 26.3+0.1 Oversize Improper offset provide in program. Freeze the offset setting and display the Inprocess check sheet on machine. 100% Inspection I.D. by Plain plug gauge 1.Work Instruction displayed for proper clamping . Perpendicularity checked by Height gauge and dial gauge. Loose assemle of part. 6 5 3 90 Taper Threading 6 3 5 90 MC Freeze the offset and Insert changing frequency setting and display the Inprocess check sheet and tool life chart on machine. Freeze the offset and Insert changing frequency setting and display the Inprocess check sheet and tool life chart on machine. Improper offset provide in program and Insert wear out. Improper offset provide in program and Insert wear out. ID 26.3+0.1 Undarsize 100% Inspection I.D. by Plain plug gauge 100% Inspection I.D. by Plain plug gauge CNC TURNING 1 ST Threding Length undersize 5 4 4 80 Assembly fitment not done. 8 4 3 96 020 CNC TURNING 1 ST 020 Freeze the offset and Insert changing frequency setting and display the Inprocess check sheet and tool life chart on machine. Freeze the offset and Insert changing frequency setting and display the Inprocess check sheet and tool life chart on machine. ID 26.3+0.1 Oversize Improper offset provide in program. Freeze the offset setting and display the Inprocess check sheet on machine. 100% Inspection I.D. by Plain plug gauge Loose assemle of part. 6 5 3 90 Wrong setting of stoper and offset in CNC machine 100% Inspection depth by Plain plug gauge Depth 9.5 0.2 Oversize Loose fitment 7 4 3 84 MC Freeze the offset and Insert changing frequency setting and display the Inprocess check sheet and tool life chart on machine. Freeze the offset and Insert changing frequency setting and display the Inprocess check sheet and tool life chart on machine. Freeze the offset and Insert changing frequency setting and display the Inprocess check sheet and tool life chart on machine. Improper offset provide in program and Insert wear out. ID 26.3+0.1 Undarsize 100% Inspection I.D. by Plain plug gauge Assembly fitment not done. 8 4 3 96 Wrong setting of stoper and offset in CNC machine 100% Inspection depth by Plain plug gauge Depth 9.5 0.2 Undarsize Not assemble in fitment 8 4 3 96 Wrong setting of stoper and offset in CNC machine 100% Inspection depth by Plain plug gauge Depth 9.5 0.2 Oversize Loose fitment 7 4 3 84 Job not clean proparlly by oprator and not seen by final inspector Crate problem in grinding process Special rod attachment provide on line for burr cleaning 100% job clean by rod and air. Burr in Pipe 3 2 5 30 Wrong setting of stoper and offset in CNC machine 100% Inspection depth by Plain plug gauge Depth 9.5 0.2 Undarsize Not assemble in fitment 8 4 3 96 Coolent concentration checked by reflectometer Coolent concentration checked by reflectometer Coolant Concentration less QA engineer fails to maintain proper coolant concentration Job not clean proparlly by oprator and not seen by final inspector add cutting oil for proper coolant concentration Crate problem in grinding process Special rod attachment provide on line for burr cleaning 100% job clean by rod and air. Size Varation in all parameter. 8 2 3 48 Burr in Pipe 3 2 5 30 Coolent concentration checked by reflectometer Coolent concentration checked by reflectometer Coolant Concentration less QA engineer fails to maintain proper coolant concentration add cutting oil for proper coolant concentration Coolant Concentration more QA engineer fails to maintain proper coolant concentration Size Varation in all parameter. 8 2 3 48 Cutting oil waste 5 1 Water leveling & Maintaining 2 10 Coolant Concentration more QA engineer fails to maintain proper coolant concentration Cutting oil waste 5 1 Water leveling & Maintaining 2 10 Marking provide on required pressure range Clamping pressure low M/c dashed,Boring tool break. Job not clamp properly 8 4 3 96 Marking provide on required pressure range Clamping pressure low M/c dashed,Boring tool break. Job not clamp properly 8 4 3 96 Clamping Pressure maintaining within marking shown on Dial indicator Clamping Pressure maintaining within marking shown on Dial indicator Marking provide on required pressure range Clamping pressuree high Collet assembly not operate properly Marking provide on required pressure range 8 Collet assembly break. 4 3 96 Clamping pressuree high Collet assembly not operate properly 8 Collet assembly break. 4 3 96 Offset lock not Added in PFMEA Offset Lock Point Added In PFMEA

INSPECTION SIDE ACTION BEFORE AFTER Identification Mark Not Provided On Ok Part. Started 100% Inspection with the help of thread plug gauge & plug gauge before supply the ETL With identification mark on Ok Part.

INSPECTION SIDE ACTION BEFORE AFTER Checking Frequency Has 5 Nos/Hour. Started 100% Inspection At Machining Stage With The Help Of TPG & Plug Gauge GO and NOGO.

ONE POINT LESSON : M26X1-6H - :- :- /

WI FOR INSERT CHANGE (OCP) SBWPL/PRD/14 : : - ( , , ) , ( , ) : , 200 / , , : ( , , )

WI FOR PLUG GAUGE CHECKING (OCP) SBWPL/PRD/14 : - ( , , ) , ( , ) : | | | , : . ( , , ) .

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