KCRC Quality Improvement Activity Signature

KLTD
Target Activity
FY18 Analysis by Defect phenomenon
1) Leakage
2) Performance issue KCRC

Engine Long block assembly process video quality cross audit

2023/＊＊/＊＊

Plant name: KI
a) Reusability

b) Assembly

c) Sub assy Auditors : KRA

d) Test Error
e) Machining

Process 1 Process 2 Process３

Safety 監査側のコメント Audi 納期 対策内容に対する監査側のコメン
Good or Video 被監査側の対策内容 Au 担当 技術 スタッフ 品保 quality 備考
No. process or Video play time Type Photo tor’s comment 参考資料 Reference material 班⾧ Team leader Schedule/ 改善した写真 Improved photo トAuditors comments on
Caution number ditee measures Person in Charge Technical staff assurance Remarks
Quality Due date countermeasures

コネクティングロッドをウエスで清掃し Air blow process

ているが、エアブローしていない。 implemented ,now air blown
sample Caution c No.1 00:01:23 The connecting rod is wiped - with air gun Anand Krishna OK OK 08 April 2022 Good Completed
with a cloth, but there is no エアブロープロセスが追加され、エア
air blow work process. ガンでエアブローされました。

Placement of cleaner was

not proper (from video no 1
Dibuatkan tempat khusus di
1 Caution b Safety No.1 00:05:07 until no 3). Potential fall Andri Agung OK OK 26 June 2023
trolley tools Assembly
down if accidentally
touched.

Proses pengecheckan
After install bushing, didn’t lubang bushing sudah di
check the holes lakukan menggunakan flash
2 Caution b Quality No.2 00:05:52 concentricity. Potential the light dan hanya saja tidak Andri Agung OK OK 26 June 2023
lubrication hole was not terlampir dalam video sudah
center. tercantum di check sheet
Assembly.

Tool guide for install

Bushing of FIP Drive was Tools still good condition.
Safety &
3 Caution b No.3 00:02:44 loosen (fall down). Potential And for installation Andri Agung OK OK 26 June 2023
Quality
the bushing was not align & bushingcan be used
the tool was damage.

tool install bushing

Tool storage too far from
diletakkan di trolley terlebih
4 Caution b Safety No.5 00:01:10 workpiece. It's better to use Andri Agung OK OK 27 June 2023
dahulu agar tidak jauh dari
movable tool trolley.
tempat kerja

Verification marking sudah

No verification marking dilakukan sebelum proses
5 Caution b Quality No.5 00:01:17 Andri Agung OK OK 27 June 2023
after tightening torque tightening torque sesuai
dengan basic assembly

Proses pemberian plug di

Loctite applied on cylinder
lakukan plug bagian ujung
block (plug hole), not on
dan menggunakan kuas
6 Caution b Quality No.5 00:04:21 plug surface. Potential the Andri Agung OK OK 27 June 2023
agar tidak berlebihan
loctite pushed in during plug
locktitenya. sesuai basic
installation.
assembly .

Stand assembly di
Manpower hand position tambahkan special base
7 Caution b Safety No.5 00:08:36 when hitting tool was not sesuai dengan ketinggian. Andri Agung OK OK 26 June 2023
ergonomics Pemasangan menjadi lebih
ergonomi.

Cylinder liner was directly Proses pressing cylinder

pressed using push tool liner dilakukan
8 Caution b Quality No.7 00:07:20 without being pressed by menggunakan tangan Andri Agung OK OK 26 June 2023
hand to ensure the o-ring terlebih dahulu lalu di tekan
was seated properly dengan mesin press 130 bar

Proses protrusion liner

Protrusion liner was not sudah di lakukan dan diukur
9 Caution b Quality No.7 00:09:30 measured after install 4 titik selanjutnya sudah Andri Agung OK OK 28 June 2023
cylinder liner tercantum di check sheet
assembly

Oli di berikan pada main

Not applied oil lubricant on metal sebelum crank shaft
10 Caution b Quality No.8 00:09:35 main metal before install di pasang. Dan sudah Andri Agung OK OK 26 June 2023
Main Cap on Cylinder Block tercantum di check sheet
assembly

Dilakukan pengecheckan
Rotating torque was not rotating torque. Sesuai
11 Caution b Quality No.9 00:11:46 checked after main cap standart prosedure. Andri Agung OK OK 26 June 2023
tightening torque Tercantum di check sheet.
Check video

Main cap bolts were not

punched after 3rd step of Dilakukan punch marking
bolts tightening torque. The pada bolts setelah
12 Caution b Quality No.9 00:10:31 Andri Agung OK OK 26 June 2023
punch process applied after tightening torque. Check
conrod installment (video video
no.11). Potential missed.

Pengecheckan end play di

lakukan. Dorong
Final endplay measurement
menggunakan bar sebanyak
of Crankshaft was not
13 Caution b Quality No.9 00:11:41 3 kali untuk memastikan Andri Agung OK OK 26 June 2023
accurate (only 1 time to
end play pada crank shaft
shift the Crankshaft)
dan tercantum di check
sheet.

Protrusion liner
measurement only applied
on 1 point for every cylinder
Protusion linner di lakukan
liner. It's better to measure
14 Caution b Quality No.10 00:00:09 pengecheckan 4 posisi Andri Agung OK OK 26 June 2023
it in 4 position to ensure
check video
evenness of cylinder liner
surface to Cylinder block
surface.

Verification marking sudah

No verification marking
dilakukan sebelum proses
15 Caution b Quality No.12 00:06:21 after bolt tightening torque Andri Agung OK OK 26 June 2023
tightening torque sesuai
(piston cooling nozzle)
dengan basic assembly

Masking workpieces after

16 Good b Quality No.12 00:10:44 Andri Agung OK OK 26 June 2023
process

Apply special tool to install

17 Good b Quality No.13 00:05:07 Andri Agung OK OK 26 June 2023
camshaft
 Trolley di geser agar
Confined space to install
pemasangan camshaft
Safety & Camshaft to Cylinder Block.
18 Caution b No.13 00:05:29 space lebih luas. dan Andri Agung OK OK 26 June 2023
Quality Potential the Camshaft
pemasangan menjadi lebih
collided with another object.
aman

Marking direction of
Verification marking sudah
mounting bolts of Oil Pump
dilakukan sebelum proses
19 Caution b Quality No.14 00:04:05 were not same and no Andri Agung OK OK 26 June 2023
tightening torque sesuai
verification marking after
dengan basic assembly
bolt tightening torque

Verification marking sudah

No verification marking
dilakukan sebelum proses
20 Caution b Quality No.15 00:03:48 after bolt tightening torque Andri Agung OK OK 26 June 2023
tightening torque sesuai
(timing gear)
dengan basic assembly

Apply oil on strainer to

21 Good b Quality No.16 00:07:52 Andri Agung OK OK 26 June 2023
prevent rust

Gunakan lock tite pada

ujubg blind plug
Not apply loctite during menggunakan kuas agar
22 Caution b Quality No.17 00:01:06 Andri Agung OK OK 26 June 2023
blind plug installment tidak berlebihan dan cara
pemasangan di lakukan
dengan benar.

Tool installer blind plug was Tools still good condition.

Safety &
23 Caution b No.17 00:01:11 bad condition on hitted And for installation blind Andri Agung OK OK 26 June 2023
Quality
surface area plug can be used

General cleaning parts

24 Good b Quality All All Andri Agung OK OK 26 June 2023
before assembly process

Perform Yosh Check during

25 Good b Quality All All Andri Agung OK OK 26 June 2023
final check process