Rework Defects Categorisation & Method of

Reworkable Rework Rework

Sr. No. Defects: /Non Identification Offline
Reworkable Mark /Online
1 BATCH CODE MISS √ R-BCM ONLINE

2 BOLT LOOSE √ R-BL ONLINE

3 BOLT THREAD TIGHT √ R-BTT ONLINE

4 MIG HOLE √ R-MH OFFLINE

5 MIG MISS √ R-MM OFFLINE

6 DENT √ R-D ONLINE

7 FLANGE DAMAGE √ R-FD ONLINE

8 HALF SPOT √ R-HS ONLINE

9 HOLE DAMAGE √ R-HD ONLINE

10 NUT BKG √ R-NB OFFLINE

11 NUT /BOLT/STUD MISS √ R-NM OFFLINE

12 NUT TIGHT √ R-NT ONLINE

13 WELD OPN MISS √ R-WOM OFFLINE

14 PART MISS √ R-PM OFFLINE

15 RUSTY √ R-R ONLINE

SEALER APPLY AT WRONG

16 √ R-SWP OFFLINE
POSITION

17 SEALER MISS √ R-SM ONLINE

18 SPATTER IN NUT √ R-SN ONLINE

19 SPOT BURR √ R-SB ONLINE

20 SPOT HOLE √ R-SH OFFLINE

21 SPOT MISS √ R-SM OFFLINE

22 SPOT PUNCTURE √ R-SP ONLINE

23 SPOT SHIFT √ R-SS OFFLINE

24 STUD BKG √ R-SB OFFLINE

25 SLUG JAM √ R-SJ OFFLINE

26 SPOT FAIL √ R-SF OFFLINE

27 FLANGE EXCESS √ R-FE OFFLINE

AXLE MIG WELDING IN

28 √ R-AMW ONLINE
IDENTIFIED REWORKABLE AREA
AXLE MIG WELDING IN
29 IDENTIFIED NON REWORKABLE X
AREA
30 CO2 EXCESS X
31 CRACK X
32 THINING X
33 FLANGE OPPOSITE X
34 FLANGE SHORT X
35 GAUGE NG X
36 GUN HOLE X
37 HOLE SHIFT X
38 STUD LENGTH SHORT X
39 HEAVY WRINKLE X
 BOX SECTION PART/
40 X
HARDWARE MISS
41 BOX SECTION SPOT MISS X
42 NUT SHIFT X
OPPOSITE SIDE PART/
43 X
HARDWARE WELD
44 PART SHIFT X
45 WRONG PART WELD X
46 STUD PUNCTURE/SHEET BURN X
47 HOLE MISS X
48 SPOT FAIL IN BOX AREA X
49 THREAD MISS X
50 MARU A SPOT MISS X
51 MARU A SPOT FAIL X
52 PRESS PART OP. MISS X

Note: All reworkable defects are subjected to feasabillity of rework i.e. position of defect and reach of rewor

Parts to be reworked by dedicated manpower only, with use of appropriate rework tool required. DPM
Method:
maintained in Defect Registrer

Prepared By: Reviewed BY :

efects Categorisation & Method of Rework

Rework Method

Refeed part at punching operation

Bolt tightened by torque wrench

1.Rethreading by Threading Die

2. Check thread by Ring Gauge

1. Hole fill by MIG welding

2. Grinding and buffing of excess weld material

MIG welding at missed places

1. Dent removal by Die and Hammer

2. Buffing at dent area for finishing

By Hammer flat the damage flange area

Extra spot weld at correct position by particular spot welding

gun

By Hammer flat the damage hole area

Rewelding of nut by particular nut welding m/c

Rewelding of Nut/ BOLT/ STUD by particular welding m/c

1.Tapping of nut
2. Checking of nut thread with plug gauge

Part reload at operation where miss occurred

Part reload at same operation where part miss occurred

If reload not posible then reject the part

Removal of rust by rubbing part with with rust removal

1. Removal of sealer from wrong position by rubbing off with

diesel
2. Apply the required sealer at required position

Apply required sealer from operation where sealer miss

1. Removal of spatter in nut by fork type tool

2. Check nut thread by plug gauge
3. IF NOT OK, do tapping in nut
4. Check nut thread by plug gauge

Removal of burr by chiesel / File

1. Co2 welding at spot hole areas
2. Grinding and buffing excess welding by grinder

1. IF respotting feasable at particular operation where spot

miss:
Refeed the part at that operation
2. IF respotting not feasable at particular operation where
spot miss:
Spot welding by gun working on required parameters
3. IF spot welding not feasable due due to gun reach: Reject
the part

1. IF spot puncture dia <1mm : Respotting at spots with

welding gun working on required parameters
2. IF spot puncture dia > 1mm : CO2 welding at spot puncture
spots

1. IF respotting feasable at particular operation where spot

shift :
Refeed the part at that operation
2. IF respotting not feasable at particular operation where
spot shift:
Spot welding by gun working on required parameters
3. IF spot welding not feasable due due to gun reach : Reject
the part

Rewelding of stud by particular stud welding m/c

Remove the slug by hammer and pin

1. IF respotting feasable at particular operation where spot

weld : Refeed the part at that operation
2. IF respotting not feasable at particular operation where
spot weld: Spot welding by gun working on required
parameters
3. IF spot welding not feasable due due to gun reach : Reject
the part

Grind the excess flange by grinder and check on inspection

gauge

MIG welding tacking done at defined station

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billity of rework i.e. position of defect and reach of rework tool.

r only, with use of appropriate rework tool required. DPM - QA / SCM-QA will approve whether rework is accepted & rejected. Records

Reviewed BY : Approved By:

Doc. No. :
Rev. No. :
Page No.: 1/2
Eff. Date:

Verification method

Visually check the punching mark and round marking done on

part
Bolt check with torque wrench at required force and line
marking done on bolt

Check thread condition by Ring Gauge

Visually check the welding area for welding shift and rough
welding

1. Visually check for welding miss.

2. Check for welding length with scale
3.Check welding strength with knocking test

Check the dent with hand feel.

Visually check the damage area and line marking for same

1. Visually check the spot position

2. Performe the NDT test to check the spot strength

Visually check the damage hole

Performe the NDT test to check the nut strength with bolt and
hammer
Visually check the hardware for miss.

Check the thread condition with plug gauge

Visually check the part for operation miss and marking for
same
1. Visually check the assy for part missand marking done on
part
2. Check the part position on inspection gauge

Visually check the part for rust

1. Check the part for required sealer and sealer position

2. Check the part for excess sealer

1. Check the part for required sealer and sealer position

2. Check the part for excess sealer

Check the thread condition with plug gauge

Visually check the part for spot burr and line marking on spot
Check the spot area for rough welding

1. Visually check for spot miss

2. Compare part with ref sample for spot position
3. Performe NDT test for spot strength

1. Visually check for spot appreance

2. Performe NDT test for spot strength

1. Visually check for spot miss

2. Compare part with ref sample for spot position
3. Performe NDT test for spot strength

1. Check part on inspection gauge for stud position

2. Check stud strength with buckling tool

Check part for hole dia and for damage

1. Compare part with ref sample for spot position

2. Performe NDT test for spot strength

Check the part on inspection gauge

Visually check part for welding apprance and welding shift

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/ SCM-QA will approve whether rework is accepted & rejected. Records of the same will be

Approved By:
 Doc. No. : 43W93
Rework Defects Categorisation & Rev. No. : 01
Method of Rework Page No.:
Eff. Date:
2/2
19.12.20

Sr. No. REWORKABLE DEFECTS METHOD OF REWORK

1 BATCH CODE MISS Refeed part at punching operation
2 BOLT LOOSE Bolt tightened by torque wrench
1.Rethreading by Threading Die
3 BOLT THREAD TIGHT
2. Check thread by Ring Gauge
1. Hole fill by Co2 welding
4 CO2 HOLE
2. Grinding and buffing of excess weld material
5 CO2 MISS Co2 welding at missed places
1. Dent removal by Die and Hammer
6 DENT
2. Buffing at dent area for finishing
7 FLANGE DAMAGE By Hammer flat the damage flange area
8 HALF SPOT Extra spot weld at correct position by particular spot welding gun
9 HOLE DAMAGE By Hammer flat the damage hole area
10 NUT BKG Rewelding of nut by particular nut welding m/c
11 NUT /BOLT/STUD MISS Rewelding of Nut/ BOLT/ STUD by particular welding m/c
1. Removal of nut with grinder
12 NUT SHIFT
2. Rewelding of nut at correct position by particular nut welding m/c
1.Tapping of nut
13 NUT TIGHT
2. Checking of nut thread with plug gauge
14 WELD OPN MISS Part reload at operation where miss occurred

1. Opposite side part/ harware cut by grinder

2. Parts load in inspection gauge
OPPOSITE SIDE PART/ 3. Marking of part position which is NG and unlaod part from inspection gauge
15
HARDWARE WELD 4. Set the part at marked position and tack spot weld
5. Required spot weld by same gun working with same parameter
6. Part check in inspection gauge for correct position part weld

1. Parts load in inspection gauge

2. Marking of part position which is missed and unlaod part from inspection gauge
16 PART MISS 3. Set the part at marked position and tack spot weld
4. Required spot weld by same gun working with same parameter
5. Part check in inspection gauge for correct position part weld

1. Part( part shift) cut by grinder

2. Parts load in inspection gauge
3. Marking of part position which is NG and unlaod part from inspection gauge
17 PART SHIFT
4. Set the part at marked position and tack spot weld
5. Required spot weld by same gun working with same parameter
6. Part check in inspection gauge for correct position part weld

18 RUSTY Removal of rust by rubbing part with with rust removal

SEALER APPLY AT WRONG 1. Removal of sealer from wrong position by rubbing off with diesel
19
POSITION 2. Apply the required sealer at required position
20 SEALER MISS Apply required sealer from operation where sealer miss

1. Removal of spatter in nut by fork type tool

2. Check nut thread by plug gauge
21 SPATTER IN NUT
3. IF NOT OK, do tapping in nut
4. Check nut thread by plug gauge

22 SPOT BURR Removal of burr by chiesel / File

1. Co2 welding at spot hole areas
23 SPOT HOLE
2. Grinding and buffing excess welding by grinder
 1. IF respotting feasable at particular operation where spot miss:
Refeed the part at that operation
24 SPOT MISS 2. IF respotting not feasable at particular operation where spot miss:
Spot welding by gun working on required parameters
3. IF spot welding not feasable due due to gun reach : CO2 welding at spot miss locations

1. IF spot puncture dia <1mm : Respotting at spots with welding gun working on required
25 SPOT PUNCTURE parameters
2. IF spot puncture dia > 1mm : CO2 welding at spot puncture spots

1. IF respotting feasable at particular operation where spot shift :

Refeed the part at that operation
26 SPOT SHIFT 2. IF respotting not feasable at particular operation where spot shift:
Spot welding by gun working on required parameters
3. IF spot welding not feasable due due to gun reach : CO2 welding at spot miss locations

27 STUD BKG Rewelding of stud by particular stud welding m/c

1. Wrong part weld cut by grinder

2. Parts load in inspection gauge
3. Marking of part position of correctpart and unlaod parts from inspection gauge
28 WRONG PART WELD
4. Set the part at marked position and tack spot weld
5. Required spot weld by same gun working with same parameter
6. Part check in inspection gauge for correct position part weld

1. Mig tacking in the puncture area

STUD PUNCTURE/SHEET 2. Grinding done by grinding wheel in tacking area.
29
BURN

Note: All reworkable defects are subjected to feasabillity of rework i.e. position of defect and reach of rework tool.

Parts to be reworked by dedicated manpower only, with use of appropriate rework tool required. SCM QA will decide
Method:
where rework is OK or NG

Prepared By: Reviewed BY : Approved By: