LESSONS LEARNT

Sl. Cell / Problem

Date Part no. Process Problem / Audit findings Analysis
No. Customer identified by
Jan-12 Avio 4P0170-B In-house on Turning Linear Dimension 24±0.25 not Due to air pressure while inserting
Turning m/c achievable the holding pin not seating on proper
1 position(clearence of the pin & Part
ID is very closely maintained)

Apr-12 Avio 2312M97P01 In-house on Turning Runout & concentricity 0.05 & 0.1 Due to more length, thickness of the
Turning m/c mm respectively not able to part is very less(2.5mm) - clamping
2 achieve pressure found more in the holding
area
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Format No.F-QA-LL-24 Page 1 of 15 Reviewed By: HOD-Quality

ESSONS LEARNT
Corrective actions Lessons learnt

Clearence of the pin & part ID Always provide the slot or

increased by reducing the OD of the pin clearence b/w the two mating
parts

ID profile mandrel used to hold in one Due to ID profile mandrel the

side & other side with centre support. clamping pressures tranffred on
mandrel

Format No.F-QA-LL-24 Page 2 of 15 Reviewed By: HOD-Quality

 Customer
Sl.No Date Entered Entered By Part No Part Photo Criticality of the part FAI Team
/Project

Srinivasan
ID boring in
Sharanappa
Turning
Ashok

Parker /
1 22.12.12 Srinivasan 476105-1
Transfer Tube

Runout between
ID to OD on Both Srinivasan
Parker /
2 22.12.12 Srinivasan 283262-1 Ends Sharanappa
Transfer Tube
Ashok
Deep hole drilling
 Runout between
ID to OD on Both Srinivasan
Ends Sharanappa
Ashok
Parker /
3 22.12.12 Srinivasan 366502-1 Deep hole drilling
Transfer Tube

Srinivasan
Deep Hole drilling
Sharanappa
4 22.12.12 Srinivasan 376167-1 Parker Ø 4.0 for 80 mm
Ashok
deep
Mallikarjun

Deep Hole drilling Srinivasan

OD turning Sharanappa
5 22.12.12 Srinivasan 382008-1 Parker
Groove diamter Ashok
critical ± 0.010 Mallikarjun
 Deep Hole drilling Srinivasan
OD turning Sharanappa
6 22.12.12 Srinivasan 382008-3 Parker
Groove diamter Ashok
critical ± 0.010 Mallikarjun

Srinivasan
Deep hole drilling
Sharanappa
7 22.12.12 Srinivasan 376202-1 Parker Ø 4.4 for 100 mm
Ashok
length
Mallikarjun

Srinivasan
484053-1 &
8 22.12.12 Srinivasan Parker Sharanappa
484053-3
Ashok
 KNOWLEDGE FOLDER
Special Process
Operators involved Fixture supplier Tool Supplier Issues Faced
Supplier

Venkatesh Murthy
Balaji
Arungiri Boring Bar grinded to do ID boring
Enterprises
Suresh

VMF ,
Salt Spray requirement
Passivation

Venkatesh Murthy
1. Taper in Fixture
Arungiri
Balaji Gun Drills by VMF , 2. Clamping Mark in part
Suresh
Enterprises Preciarb tools Anodizing 3. Runout between ID to OD 50
Subramanyam
microns
/Ganapathy
Venkatesh Murthy
1. Taper in Fixture
Arungiri
Balaji Gun Drills by VMF, 2. Clamping Mark in part
Suresh
Enterprises Preciarb tools Anodizing 3. Runout between ID to OD 50
Subramanyam
microns
/Ganapathy

Marking ,
Masking tape not available for applying
Niran Jan
PU top coat
Graphics

Venkatesh Murthy
Arungiri
Balaji Gun Drills by VMF,
Suresh
Enterprises Preciarb tools Anodizing
Subramanyam
/Ganapathy

Deep Hole Deep Hole drilling carried out at Vendor

Venkatesh Murthy drilling NDT & through precicarb tools
Balaji
Arungiri arranged by Passivation at Deep Hole drilling depth inconsistent
Enterprises
Suresh Precicarb API Belgaum Groove Diameter undersize
Tools Linear distance variation
 Deep Hole drilling carried out at Vendor
Deep Hole
through precicarb tools
Venkatesh Murthy drilling
Balaji Deep Hole drilling depth inconsistent
Arungiri arranged by
Enterprises Groove Diameter undersize
Suresh Precicarb
Linear distance variation
Tools
OD damage during machining

Venkatesh Murthy
Arungiri
Balaji Gun Drills by VMF,
Suresh
Enterprises Preciarb tools Passivation
Subramanyam
/Ganapathy

Venkatesh Murthy
VMF , Salt spray tested samples should be
Arungiri
Passivation repassivated as per AMS 2700
 SOP/Work
Lessons learned
Instructions

1. Special tool to be ordered for ID boring

As per AMS2700 , Salt spray testing to be conducted / Salt spray samples

to be repassivated as per customer requirement

Receiving Inspection not aware of the requirement.

Parts received from Passivation without repassivation .

Salt spray samples were sent to supplier & repassivated

1. In built error in fixture will be around 30 microns

2. Part runout will be 20-30 microns
3. Runout of 50 microns will not able to achieve through VMC process on
both ends
4. Drilling L/D ratio is 17 which is not advisable for VMC operation
5. New gun drills ordered .
6. Gun drill on aluminium material tried and was able to try achieve the
desired results .
6. Deep hole drilling opn performed in Gun drilling machine
7. Runout between ID to OD achieved within 30 microns on both ends
1. In built error in fixture will be around 30 microns
2. Part runout will be 20-30 microns
3. Runout of 50 microns will not able to achieve through VMC process on
both ends
4. Drilling L/D ratio is 15 which is not advisable for VMC operation
5. New gun drills ordered .
6. Gun drill on aluminium material tried and was able to achieve the desired
results .
6. Deep hole drilling opn performed in Gun drilling machine
7. Runout between ID to OD achieved within 30 microns on both ends

Special masking tape arranged from VMF

Delay in arrangement /delivery & processing 4 days

Drilling tried in VMC , Result achieved ,parts rechecked at Carl Zeiss

Customer did not accept drilling thorugh VMC method .
New gun drills ordered & tried . Result successful

1. Stopper required for maintaining linear dimensions

2. Groove diameter should be measured 100 %
3. Machine with good capability required
4. Total length should be maintained correctly before deep hole drilling
1. Stopper required for maintaining linear dimensions
2. Groove diameter should be measured 100 %
3. Machine with good capability required
4. Total length should be maintained correctly before deep hole drilling
5. Aluminium jaws were used for turning operation

Deep Hole drilling tried Inhouse Ø 4.4 mm

Gun drills of short length to be ordered

Initially no confirmation from Customer

After discussion with customer , parts were sent for repassivation
 Customer /
Sl.No Date Entered Entered By Part No Part Photo Criticality of the part
Project

1.ID boring in Turning

(J991P10-.035) fitting)
a.Lip thickness(0.46-0.38)
GE
130.06.2014 Maaz J1120P10 b.Lip Depth (0.66±0.063)
(27 Parts)
2.Symmetry of vertical tube J
fitting should be with in ±0.25
 KNOWLEDGE FOLDER
Special Process
FAI Team Operators involved Fixture supplier Tool Supplier
Supplier

Maaz,
Ranganath Venkatesh Murthy CMT &
Jayakumar, Arungiri Raghavendra
ISCAR
Sunitha, Suresh, & Shiv
Girish, Tangaraj Precision
Harsha.
R
Issues Faced Lessons learned

As oberved production simillar part 1. Introduced Dove tail mechanism to control

Symmetry of vertical tube J fitting was a.Lip thickness(0.46-0.38)
difficult to achieve with in ±0.25. b.Lip Depth (0.66±0.063
c.Symmetricity
SOP/Work
Instructions