3.

0 Quality Risk Mitigation Audit Plan (FY’23)

Product Apr’23 May’23 Jun’23 July’23 Aug’23 Sep’23 Oct’23 Nov’23 Dec’23

- Automat &
Assembly Oil hole Gauges availability, Identification
Piston Marking
Process drilling
Fine Boring Surface Treatment
calibration & handling management
- Packing

CNC Laser Side Face

Ring Packing
Turning Marking
Gap Grinding CRI
Grinding
Rail cut off KS Grinding Gas Nitriding

Engine - Leak Testing Friction Seat Eddy current Centre less Identification
Groove Grinding Washing
Valve - Packing Welding Grinding testing Grinding management

1
4.0 Quality Risk Assessment Summary - Oct’23 : Engine Valve

Product Risk Assessment area Apr’23 Mar’23 Apr’23 May’23 Jun’23 Jul’23 Aug’23 Sep’23 Oct’23 Nov’23

Centerless Grinding NA NA NA NA NA NA NA NA 90%  90% 

Groove Grinding NA NA NA NA NA NA NA 89%  86%  86% 
Eddy Current Testing NA NA NA NA NA 94%  100%  New check
points added

Leak Testing 83%  89%  89%  91%  89%  94%  95%  94%  - 76% 
Engine
Valve
Auto-gauging NA NA 80%
 85%  85%  93%  93%  93%  - -

Packing section NA NA 74%

 89%  96%  96%  94%  95%  - -

Friction Welding NA NA NA 92%  96%  98%  98%  98%  88%  -

Seat Grinding NA NA NA NA 94%  94%  88%  89%  88%  88% 

Washing NA NA NA NA NA NA NA NA NA 92% 
Criteria:-  If ≤ 80 %  If > 80 % and < 100%  If = 100%
2
4.0 Quality Risk Assessment Summary - Nov’23 : Piston

Product Risk Assessment area Mar’23 Apr’23 May’23 Jun’23 Jul’23 Aug’23 Sep’23 Oct’23 Nov’23

Gauges availability,
calibration & handling
NA NA NA NA NA NA NA 79%  89% 
Surface Treatment NA NA NA NA NA 86%  98%  96%  98% 
Fine Boring NA NA NA NA NA 86%  86%  91%  98% 
Piston Oil Hole drilling Process NA NA NA 92% 99%  99%  99%  99%  99% 
Assembly Process NA NA 67%  76%  82%  82%  89%  90%  95% 
Packing section NA 66%
 74%
 74%
 76%
 83%  87%  89%  91% 
Automat & Marking 86%  89%  91%  94%  96%  96%  96%  98%  91% 

Criteria:-  If ≤ 80 %  If > 80 % and < 100%  If = 100%

3
4.0 Quality Risk Assessment Summary - Nov’23 : Rings

Product Risk Assessment area Feb’23 Mar’23 Apr’23 May’23 Jun’23 Jul’23 Aug’23 Sep’23 Oct’23 Nov’23

Rail Cut Off NA NA NA NA NA NA NA NA 90%  100% 

Side Face Grinding NA NA NA NA NA NA NA 90%  100%
 100%

CRI NA NA NA NA NA NA 80%
 96%  100%  100%

Gap Grinding M/c NA NA NA NA NA 86%  100%  100%  100%  100%

Rings

CNC Profile Turning NA 48%  78%  97%  99%  100%

 100%  100%  100%  100% 
Packing section 78%  83%  100%  100%  100%  100%  100%  100%  100%  100% 
Laser Marking NA NA NA NA 92%  100%  100%  100%
 100%  100% 
KS Grinding NA NA NA NA NA NA NA NA NA 94% 
Criteria:-  If ≤ 80 %  If > 80 % and < 100%  If = 100%
4
4.1 Washing process : Engine Valve
Sr. No. Check Points Compliance% Nov’23
1 Route card availability 100% 
2 M/C check sheet availability 100% 
3 Mix-up valve (Should not be available) 50% 
4 Alkali pH as per check sheet (Min.8) 100% 
5 Alkali Temp. as per check sheet (70±10°) 100% 
6 Water Temp. as per check sheet (70±10°) 50% 
7 No blockage of water suction filter 100% 
8 No blockage of alkali suction filter 100% 
9 Nozzle cleaning no blockage 100% 
10 Water tank cleaning (Should be cleaned) 100% 
- Model mix up
11 No blockage of Blower filter
- Process parameter not adhered like water temp.
100% 
12 No Oil & water leakage 100% 
Overall Compliance %age 92% 
Criteria:-
 Score≤ 80%
  Score> 80% but < 100%   Score = 100% 5
4.1 Washing process : Engine Valve
Sr. No. Check Points Compliance% Nov’23
1 Route card availability 100% 
2 M/C check sheet availability 100% 
3 Mix-up valve (Should not be available) 50% 
4 Alkali pH as per check sheet (Min.8) 100% 
5 Alkali Temp. as per check sheet (70±10°) 100% 
6 Water Temp. as per check sheet (70±10°) 50% 
7 No blockage of water suction filter 100% 
8 No blockage of alkali suction filter 100% 
9 Nozzle cleaning no blockage 100% 
10 Water tank cleaning (Should be cleaned) 100% 
11 No blockage of Blower filter 100% 
12 No Oil & water leakage 100% 
Overall Compliance %age 92% 
Criteria:-
 Score≤ 80%
  Score> 80% but < 100%   Score = 100% 6
4.2 Leak Testing : Engine Valve
Compliance
Sr. No. Check Points
(Nov’23)
1 Master valve availability (Seat Roundness) 100% 
2 Master valve availability (Effective length-SOR) 100% 
3 Pressure drop during testing 100% 
4 Testing time 100% 
5 Charging pressure/Judgment press 86% 
6 Hammer pressure 100% 
7 LT Fixture – Required model Vs Actual fixture used 100% 
8 Leak testing fixture life monitoring 0% 
9 Rubber pad condition (Circular shape , No damage & crack) 100% 
10 LT confirmatory marking unit (No ink overflow from base tray) 100% 
11 No taper Clamping of valve during confirmatory marking 100% 
12 No ink on output magazine/Chute 100% 
13 Insertion pressure more than spec. (0.45~0.55 MPa) 52% 
14 Pusher / ejector Pressure as per WI (0.2~0.3 MPa) 29% 
15 Pressure charging time (0.1 Sec.) 52% 
- No monitoring of LT fixture life
16 Head support dia. (OD Dia. +2.0 mm min) 14% 
- Process parameter not adhered like air insertion pressure, pusher pressure
17 No wear & tear - O ring 100% 
-
18 LT fixture Guide sizeMore clearance in LT fixture guide
(Clearance) 38% 
19 Valve tip alignment w.r.t. Ejector rod 86% 
Overall Compliance %age 76% 
Criteria:-
 Score≤ 80%   Score> 80% but < 100%   Score = 100% 7
4.3 Gauges availability, calibration & handling : Piston

Sr. No. Check Points Compliance% October’23 Compliance% November’23

1
Availability, Adequacy and display of Gauge calibration rule at work
stations 75%  85% 
2 Awareness for usage of calibrated gauge on lines 85%  100% 
3 Availability of required gauges on line 85%  95% 
4 Adherence to usage of calibrated gauges with required colour coding 80%  90% 
5 Gauge condition monitoring in lines 80%  85% 
6 - Non
Awareness availability
among of gauge
associates for proper onthrough
inspection inspection
station gauges 75%  80% 
- Inspection status not identified properly on fixtures
7 Proper calibration identification marking on fixtures 75%  85% 
Overall Compliance %age 79% 89% 
Criteria:-
 Score≤ 80
  Score> 80% but < 100%   Score = 100%
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4.4 KS Grinding M/c: Ring Plant

Sr. No. Check Points Compliance status Nov’23

1 Availability of latest WI and visual standard. 100% 

2 Input & Output location defined for trolley and inspection ring 100% 
3 Is the direction for placing the ring on the trolley fixed? 70% 
4 Rejection location available on each inspection table with rejection identification. 100% 
5 Display and adherence to Mix-up rule. 100% 
6 Is it supposed that there is no ring other than the designated place? 60% 
7 Process card holding location define on trolley. 100% 
8 Instrument calibration / verification status 100% 
9 Does identification using "under process" · "process finished" identification tag? 100% 
- Ring direction alignment rule not followed
10 Record available for rejection and good Qty.
- Rings kept without proper identification in WIP
100% 
11 Are there any storage for nonconforming products? 100% 
Overall Compliance %age 94%

Criteria:-  Score≤ 80%   Score> 80% but < 100%  Score = 100% 9