KOBELCO ISSUES AND ACTIONS

1 Subject
► Discussion on Recent Nonconformities and the Action Plans.

2 Location
► DY POWER INDIA PVT LTD

2 Date
► 2024.03.12

3 Agenda
S.N Issue Description Evidance Root Cause Action Plan
1.Packing Issue:Cylinder not fully cover with the plastic cover 1.Cylinder fully covered with the plastic bag
2.Transit Issue -Uncovered the cylinders without tarpauline 2.Vehicle fully covered with a cover good tarpaulin
3.Primer DFT -Low primer DFT 3.Primer Painting Thickness increased over 60㎛
4.Process Issue: stop for a long-term in pretreatment , the rust 4.Empty Pre treatment line when shift end or stop for long time
might start from degreasing to phosphating 5.Seperate air dryer installed before primer painting to remove moisture from air.
5.Process Issue:Mositure availble in primer painting air line 6.With Adhesion test Scratch test also performed on Actual cylinder tube surface on
1 Blister Issue 6.Inspection Issue:Previously there is adhesion test performed sample basis after painting
only on Tube sample 7.Daily Nozzle Cleaning frequency increased Upto N2/Shift.
7.Process Issue:Pretreatment line Nozzle stuck (Old N1/Shift)Cleaning check sheet updated(Doc.No:DYP/RE/MAIN/12)
8.Will change the Primer PPG korea to Kansai nerolac India.(4m Request will be
send)

1.Dust cover rubber stick on flange due to High painting Oven 1.We have share the dust cover removal process as a immediate action.
temp.(90°C) 2.We are going to change the dust cover as per Wipro,so due to price issue
Dust Cover Tight searching for another supplier
2
Issue

1.Verifification of all inhouse stock_Found OK

2.We have given the awareness training to all concern operators.
3.Issue OPL has been attached on line
3 Pin Bush Crack -

- 1.We have checked the test report of defective cylinder,found Ok

2.after receive the cylinder will check again.

4 Cushioning issue
 Remark

time
ve moisture from air.
cylinder tube surface on

MAIN/12)
4m Request will be

diate action.
ue to price issue

tors. Cylinder not

received.after
received will share
the analysis report

d Ok
Cylinder not
received.after
received will share
the analysis report
 KOBELCO BLISTER ISSUE SUMMARY REPORT
Date:07.02.2024
1 Root Cause & Improvement Details:
S.N Root Cause Statement Recommended Actions Evidence Responsibility Status Remark

#Packing Issue:Cylinder not fully 1.Cylinder fully covered with the Completed
1 DYPI OK
cover with the plastic cover plastic bag 02.12.2023

#Transit Issue -Uncovered the 1.Vehicle fully covered with a Completed

2 DYPI OK
cylinders without tarpauline cover good tarpaulin 02.12.2023

1.Primer Painting Thickness Completed

3 #Primer DFT -Low primer DFT DYPI Ok
increased over 60㎛ 05.12.2023

#Process Issue: stop for a long-

term in pretreatment , the rust 1.Empty Pre treatment line when Completed
4 DYPI Ok
might start from degreasing to shift end or stop for long time 05.12.2023
phosphating

1.Seperate air dryer installed

#Process Issue:Mositure availble Completed
5 before primer painting to remove DYPI OK
in primer painting air line 07.12.2023
moisture from air.

1.With Adhesion test Scratch test

#Inspection Issue:Previously OK_Inspection
also performed on Actual cylinder Completed
6 there is adhesion test performed DYPI report attached
tube surface on sample basis after 07.12.2023
only on Tube sample seperatly
painting

1.Daily Nozzle Cleaning frequency

increased Upto N2/Shift.
#Process Issue:Pretreatment line Completed OK_Checksheet
6 (Old N1/Shift) - DYPI
Nozzle stuck 05.12.2023 attached seperatly
2.Cleaning check sheet updated
(Doc.No:DYP/RE/MAIN/12)

2 Conclusions
2.1 We have revisited our painting process ,we found there is some process gap during the primer painting .
2.2 Also there was a some packing & transportation error,which may affect on cylinder blister issues.
2.3 After detail analysis we have taken the sufficient preventive actions in process and packing side for improvement.
2.4 After implementation of all action ,we didn’t found any blister issue at customer end in improved lots.
2.5 On the basis of action implemented from our side and results we have got,we are closing the paint blister issue from our side.
 DY Plant wise Storage Cylinder Condititon
Painting Blister Issue
DYP Plant Customer Location
(Last 1 year)

DYP China KOBELCO Japan None

Europe None

HITACHI Japan None

China None

DYP Korea TIERRA Japan None

TAKEUCHI Japan None

Japan None
KOBELCO
India YES
DYP India KOBELCO India YES
DY Plant wise Storage Cylinder Condititon
Storage environment
 DUST COVER REMOVA
u Dust Cover removal process as per below:

1 2 3

Remove the all bolt of dust cover by All Dust cover bolt removed
Dust cover tight Condition
Spanner/Torque Wrenche condition
VER REMOVAL PROCESS

4 5

ust cover bolt removed Insert Screw Driver flat edge from
Dust cover removed easily
tion one side of dust cover and open it.
 Document number DYP/RE/QA/32
ONE POINT LESSON Revision Number 00
Rev.Date 3/24/2017
Basic Knowledge m OPL NO.
To Check and Ensure the Pinbush Condition during pinbush
THEME pressing (Damage ,crack)at KL & HC side
Improvement Idea m
138
Problem l

NG OK

Pin bush
OK-No
Crack,Damage
Crack etc

Don’t Pass the Defective pinbush to next process Pin Bush should be OK before and after Press

Date 20.01.2024
Records of Lessons Issued By Quality
Issued to Production

Prepared By:-Deepak P Reviewed By:-Yogesh S Authorised By:- DH Kim