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M/S .Shriram foundry ltd. kolhapur

M/S .Shriram foundry ltd. kolhapur. PART NAME: FLYWHEEL HOUSING PART No: R502439 , R120751. SUBJECT:- “DOWEL HOLE POSITION” OUT OF PRINT. ENGINE SIDE DOWEL POSITION. SFL Unable to achieve as per print. i.e.0.025mm. TRANSMISSION SIDE DOWEL POSITION.

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M/S .Shriram foundry ltd. kolhapur

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  1. M/S .Shriram foundry ltd. kolhapur PART NAME: FLYWHEEL HOUSING PART No: R502439 , R120751. SUBJECT:- “DOWEL HOLE POSITION” OUT OF PRINT ZANVAR GROUP OF INDUSTRIES

  2. ENGINE SIDE DOWEL POSITION SFL Unable to achieve as per print. i.e.0.025mm ZANVAR GROUP OF INDUSTRIES

  3. TRANSMISSION SIDE DOWEL POSITION SFL Unable to achieve as per print. i.e.0.025mm ZANVAR GROUP OF INDUSTRIES

  4. DEVELOPMENT • In Year 2001, we had developed & started machining of R502439 & R120751 flywheel housing on HMC, that time we were getting Dowel hole position up to 0.2 mm. • We had taken lot of trial to achieve position, but unable to achieve as per print. • We were supplying to you ‘OK’ component with 100% segregation and balance qty. were rejecting straight-way. • At this stage SFL in house rejection for dowel hole position was 20% - 25%. ZANVAR GROUP OF INDUSTRIES

  5. Dowel Hole position Rejection % on HMC

  6. This called for a decision ,to go for SPM with Fixed spindle heads for getting better accuracy in CD Dimn. and positions. • Accordingly we designed & introduced new SPM with fixed spindle Head • ( mfg. at Kolhapur.) in June 2003 .as shown in picture • Where both side dowels and seal bore & starter motor bore are produced at a time. FIXED SPINDLE HEAD ZANVAR GROUP OF INDUSTRIES

  7. Rejection trend after introducing SPM

  8. TRIAL TAKEN FOR ACHIEVE POSITION • After introducing SPM ,with manual clamping we improved result by 15%. But still the position was out of print. • After this we introduced hydraulic clamping (replacing manual clamping) with specific pressure, And Controlled in flatness ,But still there was no major impact on the position. • We approached for technical help, to JD for this matter. • JD Experts visited at our works for resolving this issue. • Our joint efforts also could not lead us nearer to the print requirements. ZANVAR GROUP OF INDUSTRIES

  9. After taking Trials , Rejection

  10. After taking Trials , Rejection

  11. At this stage even our in-house rejection is more than 18% which is major loss for us.(which we bear daily, to meet your schedule time to time.) • And, we are continuously in touch with JD team. (Please see attached correspondence)

  12. OUR ANALYSIS • In our Opinion , • Following Points need to be re-considered • CD & position for length 275mm and length 406mm. • (which are same in the print). • Effect of Flatness(0.25) on the position for both lengths. • Temperature variation, during day & night. • CMM to CMM inspection Variation . • Damages in transits (improper Stacking by transporter). • Identical parts drawings of other customer • showing wide tolerances are attached for your ready reference. ZANVAR GROUP OF INDUSTRIES

  13. INHOUSE REJECTION FOR ‘DOWEL POSITION’ ZANVAR GROUP OF INDUSTRIES

  14. CUSTOMER END REJECTION N C from Jul – 2010 to October -2011 ZANVAR GROUP OF INDUSTRIES

  15. THANK YOU ! Shriram foundry ltd. kolhapur ZANVAR GROUP OF INDUSTRIES

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