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Quality Issue 3001603

The document details a completed supplier complaint regarding porosity in the NP126049 material supplied by OMNI AUTO LIMITED, with issues identified during visual and magnetic particle inspection. Despite investigations, no definitive root cause was established, leading to the conclusion that permanent corrective actions could not be implemented. Recommendations for process modifications and increased inspection measures were suggested to prevent recurrence of the defect.

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KshirabdhiTanayaSwain
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24 views3 pages

Quality Issue 3001603

The document details a completed supplier complaint regarding porosity in the NP126049 material supplied by OMNI AUTO LIMITED, with issues identified during visual and magnetic particle inspection. Despite investigations, no definitive root cause was established, leading to the conclusion that permanent corrective actions could not be implemented. Recommendations for process modifications and increased inspection measures were suggested to prevent recurrence of the defect.

Uploaded by

KshirabdhiTanayaSwain
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 3

Issue No.

: 3001603

Issue Status: Completed

Type: Supplier Complaint


Start Date: 10/13/2021

Report Date: 02/27/2025

_
Header data
8D Title: Porosity in NP126049
Material: CONE-HS-NP126049-000HS;WE Material No.: 290024941
Vendor: OMNI AUTO LIMITED Vendor No.: 20221014
Authoring Facility: Chennai (INJA)
D1 - Team
Role First Name Last Name E-Mail
Person Responsible Swarup Mandal swarup.mandal@timken.com

Author Gattam Ananta gattam.ananta@timken.com

Supplier Quality Contact Kshirabdhi T.Swain qualitysc@omniauto.in


Timken SQD Manager Murali Nagaraj murali.nagaraj@timken.com

Interested Party Murali Nagaraj murali.nagaraj@timken.com

Printed on 02/28/2025 00:32:08 by E_SWAINKSH Page 1 of 3


Role First Name Last Name E-Mail

Interested Party Palani Arumugam palani.arumugam@timken.com


Facility QA Manager R. Satishkumar satish.satishkumar@timken.com

Interested Party Venkataramana M venkataramana.m@timken.com


D2 - Problem Description
Porosity in NP126049
Observed porosity in NP126049 after grinding during Visual/MPI, supplied by OMNI as hard stock. 2Nos rejected out of
99Nos received as first forging lot of L21I3, suspected steel heat is 401957. 92Nos received as second forging lot, in
that 19Nos ground and shipped along with entire first forging lot. 73Nos available as hard stock in plant from second lot
and 16Nos at supplier. Rejected ring analysis and UT test done by TERI confirms porosity due to over heating. 42
out of 189Nos rejected in immerse UT, another 296 assemblies in inventory for inspection.
Issue Supplier Complaint Defect Number of
Code: Complaint Code: Parts Affected: 42

D3 - Containment Action(s)
Containment: Determine if Required
No inventory available for the batch.
Responsible: Completion
Expected End: 04/08/2022 02/07/2023
Date:

D4 - Root Cause(s)
Mechanical Error in Flapper System
Mechanical error in Flapper System.

Temperature recorder not working in SCAD


Temperature recorder not working in SCADA.

Due to overheating at rolling process


Due to overheating at rolling process

May be process deviation from approved p


May be process deviated from approved process by Timken.

D5 - Chosen Permanent Corrective Action(s)


We have verified the flapper mechanism. However there was no error observed by us as well as by GMQ & SQD team
during their visit to OMNI. All the records ware verified by the team. Hence this can't be concluded as root cause of the
issue.

Printed on 02/28/2025 00:32:08 by E_SWAINKSH Page 2 of 3


We have verified the SCADA recorder. The record shows exactly whatever we have produced during the batch
processed at forging. Forging graph is attached for reference. Also all the data verified by GMQ / SQD during their visit.
Hence this can't be concluded as root cause of the issue.
However we have re verify the In-Process & Set up approval sheet for the produced batch in which no deviation was
observed. The same is attached for reference. Also if overheat generated in Rolling process , then this should be
observed 100% of the pieces not in 10 ~ 20% of the lot. Hence this can't be concluded as root cause of the issue.
1.GMQ and SQD representative visited in Oct-21, we have produced 20 pieces where you have witnessed that we
have followed the process which was approved during the PPAP lot. Also you have witnessed that we have not violated/
deviated any requirement specified in Timken corporate standard for the forging operation. In this lot also you have
found 2-3 pieces with defect.Hence this can't concluded as root cause of the issue. 2.Re PPAP - Trail Carried out on NP
126049 - for 49 Nos on March 30 and UT test carried out for all the Part Number refer the attached UT Report all the
parts are found ok and 49 Nos has been dispatched to chennai plant need the grinding feed back for the parts (Refer
the attached UT Report)
D6 - Implemented Permanent Corrective Action(s)
Any permanent corrective action not possible as the root cause was unconcluded.
Any permanent corrective action not possible as the root cause was unconcluded.
Any permanent corrective action not possible as the root cause was unconcluded.
1.Based on the root cause analysis as well as based on the audit evidenced by Timken GMQ/SQD, we are unable to
conclude any root cause. 2..Re PPAP - Trail Carried out on NP 126049 - for 49 Nos on March 30 2023 and UT test
carried out for all the Part Number refer the attached UT Report all the parts are found ok and 49 Nos has been
dispatched to chennai plant need the grinding feed back for the parts (Refer the attached UT Report)
D7 - Action(s) to Prevent Recurrence
Please refer to attached PPT in which Omni is suggesting process modification which may reduce the severity of the
defect generated. Also we have taken trial of 4 Nos. for which Customer's UT result is attached for reference. As per
Timken requirement we have implemented microstructure inspection for overheating which having frequency & sample
size , n=1 , during 1st time development. Process documents are modified and attached for reference.
D8 - Congratulate Your Team
Result:
Thank you.
Close Date: 11/18/2022

Printed on 02/28/2025 00:32:08 by E_SWAINKSH Page 3 of 3

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