Machining Rejection Summary Machining Defe

THREAD DAMAGE

HEIGHT UNDER/S
THREAD O/SIZE
THREAD U/SIZE

THICKNESS U/S

GROOVE DIA.
FACE/ID/OD
OD OVALITY

THICKNESS
Total Rej % as

STEP ON

C.D OUT
OD.U/S

U/SIZE
TAPER
ID.O/S
TOTAL PRODUCTION TOTAL MACHINING REJ. TOTAL CASTING per Qty Rework qty
SR.NO. PART NO. Rework qty
QTY. QTY. REJ. QTY. (Casting + %
Machining)

1 10005724(R.H) 17211 875 1733 15.2% 663 3.9% 70 1 0 0 0 0 18 6 182 145 0 86

2 10005724(L.H) 15809 822 1353 13.8% 595 1.4% 46 1 0 0 0 0 35 0 168 158 0 104

3 10005789(R.H) 20632 2025 1230 15.8% 4241 22.2% 31 1 0 0 0 0 78 0 1291 87 0 52

4 10005789(L.H) 20632 1879 1279 15.3% 5155 25.0% 18 2 0 0 0 0 42 0 1223 75 0 75

Grand Total 74284 5601 5595 15% 10654 14% 165 5 0 0 0 0 173 6 2864 465 0 317

OVERALL REJECTION SUMMARY MACHINING 700

600
REJECTION SUMMAERY AS PER % Total Rework in nos 500

400

10654 300
OVERALL TOTAL REJN. 15.07% 200

14% 100
MACHINING REJN. 7.54% 0
/S /S TY ZE ZE E /S /S SS D ZE T T G G T G G T E ZE
.O .U LI SI SI AG U ER E /O SI OU OU N IN EN IN N EN SIZ SI S
- ID OD VA U/ O/ AM ESS ND ICKN /ID . U/ .D ON FILE SETT CID TER FER D O/ .O/ .U/
O AD D D N U H CE IA C TI O AC HAT AM H IA IA
CASTING REJN. AFTER MACHINING 7.53% OD RE REA AD HICK GHT ER T FA E D SI PR C CH PT D R D O
TH TH HRE T EI AP ON OV PO DE NOR JO TO
H T P I A
T E RO M M
ST G

99%
1200 96% 98%
92%
87%
TAPER THICK 985 985 47%
OTHERS 255 1240 60% 1000 985 81%
THICKNESS U/ 173 1413 68% 75%
C.D OUT 149 1562 75%
STEP ON FACE 124 1686 81%
68%
SETTING 120 1806 87%
800
60%
CHATTERING 103 1909 92%
ID.O/S 84 1993 96%
DENT 44 2037 98% 600 47%
CHAMFER NG 25 2062 99%
TOOL BROKEN 9 2071 100%

Quantity
PROFILE NG 2 2073 100%
ACCIDENT 1 2074 100% 400
THREAD U/SI 0 2074 100%
THREAD DAM 0 2074 100% 255
THREAD O/SI 0 2074 100% 200 173 149
POWER OFF 0 2074 100% 124 120 103
POSITION OUT 0 2074 100% 84
44 25
OD.U/S 0 2074 100%
OD OVALITY 0 2074 100% 0
S S S T D G G S T G
MINOR DIA.O/ 0 2074 100%
NES HER U/ OU /O TIN RIN .O/ EN R N
MAJOR DIA.U/ 0 2074 100% K OT ES S D /I D T E I D D E R
C . E T F
HEIGHT UNDE 0 2074 100% HI KN
C CE S AT
AM L
B
 99%
1200 96% 98%
92%
87%
1000 985 81%
75%
68%
800
60%

600 47%

Quantity
400
255
200 173 149
124 120 103
84
44 25
0
SS RS /S UT OD NG NG /S NT NG
K NE THE SS U D O ID/ TTI ERI ID.O DE ER
IC O NE C. E/ SE TT F BR
TH I CK F AC HA H AM O L
GROOVE DIA. 0 2074 100% R C C TO
PE TH ON
TA
DEPTH O/SIZE 0 2074 100%
EP
ST
2074
 Machining Defects Casting Defects after machining Rework

MAJOR DIA.U/SIZE

EXTRA MATERIAL
SAND INCLUSION

THICKNESS O/S
FACE UNCLEAN
POSITION OUT

THICKNESS NG
TOOL BROKEN
DEPTH O/SIZE
CHATTERING

CHAMFER NG

Step on face
PROFILE NG

BLOW HOLE
POWER OFF

PROFILE NG

SHRINKAGE
DIA.O/SIZE
ACCIDENT

Height NG
SETTING

DIA. U/S
OTHERS

OTHER

OTHER
MINOR

CRACK
DENT

DENT

DENT
SLAG

SLAG
0 0 63 20 15 99 26 0 0 0 25 0 119 131 25 10 12 190 142 604 606 0 5 0 8 15 0 0 0 439 209

0 4 36 21 69 36 31 0 0 0 5 1 107 161 27 13 11 125 87 464 495 0 9 0 18 25 0 0 0 0 195

0 1 63 1 71 11 16 0 0 0 5 0 317 101 31 6 10 28 183 209 563 1 62 0 104 10 0 0 0 4546 21

0 0 65 0 57 19 11 0 0 0 6 0 286 65 28 8 6 33 144 214 545 0 25 0 211 8 0 0 0 5095 52

0 5 227 42 212 165 84 0 0 0 41 1 829 458 111 37 39 376 556 1491 2209 1 101 0 341 58 0 0 0 10080 477

T G G T G G T E ZE ZE N FF RS LE N K AL G NT GE AG NG AN NG ER
OU N IN EN IN N EN SIZ SI SI KE O E O IO AC RI N
DE NKA SL ght CLE ESS OTH
N FILE SETT CID TER FER D O/ .O/ .U/ RO ER OTH W H LUS CR ATE FILE i
O AC HAT AM T H DIA DIA L B OW O NC M RO RI N
He E U ICKN
P R C CH P R O P L
B D I A P SH C H
DE NOR JO TO N TR FA T
I
M M
A SA EX

Chart Title
96% 98% 99%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100% 100%
92%
87% 90%
81%
% 80%

70%

60%

50%

40%
Cum.%

30%

20%
9 124
120 103
84 10%
44 25 9 2 1 0 0 0 0 0 0 0 0 0 0 0 0
0%
D G G /S T G N G T ZE GE ZE FF UT /S TY ZE ZE /S ZE ZE
/O TIN RIN .O DEN R N OKE E N DEN /SI A SI O O . U LI SI SI R SI I
I D ET TE I D F E R I L C I U A M O/ ER N OD VA .O/ .U/ NDE . U/ O/S
S AT M L B O F C D D D W I O O I A I A U I A H
A A A A O IT D D T T
 Chart Title
99%100%100%100%100%100%100%100%100%100%100%100%100%100%100%100%
96% 98% 100%
92%
87% 90%
81%
% 80%

70%

60%

50%

40%

Cum.%
30%

20%
9 124
120 103
84 10%
44 25 9 2 1 0 0 0 0 0 0 0 0 0 0 0 0
0%
D G G /S NT NG EN NG NT IZE GE IZE FF UT U/S ITY IZE IZE R/S IZE IZE
/O IN IN .O DE ER ROK ILE IDE U/S MA O/S ER O N O D. VAL O/S U/S DE U/S /S
ID ETT TER ID F B
S AT F C A
AC EAD D D AD OW SITI
O O O A. A. UN IA. TH O
AM OL PRO D DI R DI HT
CH H
C T O R A RE P O O R E D DEP
TH HRE TH P
I
G
NO AJO HEI OV
T M M O
GR

Defects

Column I Column K
 MACHINING REJECTION MONITORING SHEET

Rework
Total Rej
Total
Total Total Rej Total % as per
WEEK

THREAD O/SIZE
Total Rej Casting

THREAD U/SIZE
Part No.

OD OVALITY
Production Qty Machining Qty
NO. Qty Casting Rejection Total

OD.U/S
Qty Machining Rejection % (Casting +

ID.O/S
% Rework %
Rework Qty Machining)

10005724(R.H) 1740 106 6.1% 254 14.6% 25 1.4% 20.7% 18 0 0 0 0

WEEK - 1
01-05 Jan

10005724(L.H) 1695 110 6.5% 215 12.7% 26 1.5% 19.2% 17 0 0 0 0

10005789(R.H) 2371 386 16.3% 209 8.8% 270 11.4% 25.1% 8 0 0 0 0

10005789(L.H) 2371 320 13.5% 227 9.6% 323 13.6% 23.1% 9 0 0 0 0

TOTAL 8177 922 11.3% 905 11.1% 619 7.57% 22.3% 52 0 0 0 0

11.3% 11.1% 7.0% 22.3%

10005724(R.H) 4341 369 8.5% 492 11.3% 267 6.2% 19.8% 31 0 0 0 0

WEEK - 2
06-12 Jan

10005724(L.H) 3762 220 5.8% 297 7.9% 158 4.2% 13.7% 9 1 0 0 0

10005789(R.H) 5886 528 9.0% 282 4.8% 1425 24.2% 13.8% 17 0 0 0 0

10005789(L.H) 5886 610 10.4% 442 7.5% 1639 27.8% 17.9% 2 0 0 0 0

TOTAL 19875 1727 8.7% 1513 7.6% 3489 17.6% 16.3% 59 1 0 0 0

8.7% 7.6% 15.6% 16.3%

10005724(R.H) 4987 167 3.3% 448 9.0% 215 4.3% 12.3% 9 1 0 0 0

WEEK - 3
13-19 Jan

10005724(L.H) 4192 162 3.9% 275 6.6% 186 4.4% 10.4% 7 0 0 0 0

10005789(R.H) 6415 591 9.2% 445 6.9% 1327 20.7% 16.1% 4 1 0 0 0

10005789(L.H) 6415 463 7.2% 354 5.5% 1693 26.4% 12.7% 3 2 0 0 0

TOTAL 22009 1383 6.3% 1522 6.9% 3414 15.5% 13.2% 23 4 0 0 0

6.3% 6.9% 14.0% 13.2%

10005724(R.H) 6143 233 3.8% 539 8.8% 156 2.5% 12.6% 12 0 0 0 0

K-4
6 Jan

10005724(L.H) 6160 330 5.4% 566 9.2% 225 3.7% 14.5% 13 0 0 0 0

WEEK - 4
20-26 Jan
10005789(R.H) 5960 520 8.7% 294 4.9% 1219 20.5% 13.7% 2 0 0 0 0

10005789(L.H) 5960 486 8.2% 256 4.3% 1500 25.2% 12.4% 4 0 0 0 0

TOTAL 24223 1569 6.5% 1655 6.8% 3085 12.7% 13.3% 31 0 0 0 0

6.5% 6.8% 13.0% 13.3%

10005724(R.H) 0 0 #DIV/0! 0 0 #DIV/0! #REF! 0 0 0 0 0

WEEK- 5
27-31 Jan

10005724(L.H) 0 0 #DIV/0! 0 0 #DIV/0! #REF! 0 0 0 0 0

10005789(R.H) 0 0 #DIV/0! 0 0 #DIV/0! #REF! 0 0 0 0 0

10005789(L.H) 0 0 #DIV/0! 0 0 #DIV/0! #REF! 0 0 0 0 0

TOTAL 0 0 #DIV/0! 0 0 #DIV/0! 0 0 0 0 0

#DIV/0! #DIV/0! #DIV/0!

Week 2

TAPER THICKNESS 642 642 56%

OTHERS 99 741 64% Pareto
SETTING 92 833 72%
75 908 79% 700 99% 100%100%100%100%100%100%100%
THICKNESS U/S
642 96% 98%
STEP ON FACE/ID/OD 74 982 85% 93%
90%
CHATTERING 53 1035 90% 600 85%
C.D OUT 39 1074 93% 79%
ID.O/S 32 1106 96% 500 72%
CHAMFER NG 19 1125 98%
64%
DENT 18 1143 99%
TOOL BROKEN 7 1150 100% 400 56%
PROFILE NG 1 1151 100%
ACCIDENT 1 1152 100% 300

Quantity
OD.U/S 0 1152 100%
OD OVALITY 0 1152 100% 200
THREAD U/SIZE 0 1152 100%
THREAD O/SIZE 0 1152 100% 99 92
100 75 74
THREAD DAMAGE 0 1152 100% 53 39 32
HEIGHT UNDER/S 0 1152 100% 19 18 7 1 1 0 0 0 0 0
GROOVE DIA. U/SIZE 0 1152 100% 0
POSITION OUT 0 1152 100% SS RS NG /S D NG UT /S NG NT EN NG NT U/S ITY IZE IZE GE
KNE THE TTI SS U ID/O ERI D O ID.O ER DE ROK ILE E .
ID OD VA
L S
U/ O/ AM
S A
DEPTH O/SIZE 0 1152 100%
H IC O SE NE CE/ ATT
K C. M
F
L B OF
ACC O AD D D U
MINOR DIA.O/SIZE 0 1152 100%
ER
T C
HI N F
A
CH CH
A
OO PR OD HRE REA EAD GHT
MAJOR DIA.U/SIZE 0 1152 100% P T T T H R I
POWER OFF 0 1152 100% TA EP
O T
TH HE R O
ST G
1152
Defects

Column D Column F
 Machining Defects Casting Defects after machining Rewor

STEP ON FACE/ID/OD

GROOVE DIA. U/SIZE

TAPER THICKNESS

MAJOR DIA.U/SIZE
MINOR DIA.O/SIZE
THREAD DAMAGE

HEIGHT UNDER/S

EXTRA MATERIAL
SAND INCLUSION
THICKNESS U/S

TOOL BROKEN
POSITION OUT

FACE UNCLEAN
CHAMFER NG
CHATTERING

THICKNESS NG
DEPTH O/SIZE
PROFILE NG

POWER OFF

BLOW HOLE

PROFILE NG

SHRINKAGE
ACCIDENT

Height NG
SETTING

OTHERS
C.D OUT

DIA. U/S
OTHER
CRACK
DENT

DENT

DENT
SLAG

SLAG
0 10 0 36 5 0 18 0 0 0 0 3 5 5 0 0 0 0 0 6 30 2 1 0 104 26 13 74 0 0 0 4 9 0 0

0 34 0 1 9 0 18 0 1 0 0 15 1 12 0 0 0 0 0 2 29 6 0 0 65 13 47 50 0 0 0 5 16 0 0

0 46 0 142 20 0 25 0 0 16 0 15 0 5 0 0 0 0 0 109 27 6 0 1 6 32 39 80 0 11 0 7 0 0 0

0 8 0 164 16 0 49 0 0 12 0 17 0 4 0 0 0 2 0 39 17 6 0 0 18 36 26 88 0 0 0 36 0 0 0

0 98 0 343 50 0 110 0 1 28 0 50 6 26 0 0 0 2 0 156 103 20 1 1 193 107 125 292 0 11 0 52 25 0 0

0 8 0 79 57 0 39 0 0 47 8 8 48 7 0 0 0 3 0 34 29 2 7 2 31 22 286 112 0 1 0 0 6 0 0

0 1 0 56 41 0 28 0 2 17 1 25 0 10 0 0 0 0 0 29 19 6 11 0 20 24 175 93 0 2 0 4 2 0 0

0 32 0 330 31 0 13 0 1 31 0 19 4 3 0 0 0 2 0 45 18 7 6 0 4 41 62 110 0 44 0 58 0 0 0

0 34 0 430 20 0 8 0 0 37 0 15 3 3 0 0 0 2 0 56 7 9 8 0 4 34 87 154 0 20 0 119 3 0 0

0 75 0 895 149 0 88 0 3 132 9 67 55 23 0 0 0 7 0 164 73 24 32 2 59 121 610 469 0 67 0 181 11 0 0

0 0 6 34 20 0 11 0 0 2 3 3 25 8 0 0 0 8 0 37 45 8 1 5 36 47 154 147 0 2 0 3 0 0 0

0 0 0 49 26 0 9 0 0 2 10 4 13 4 0 0 0 4 0 34 38 7 1 1 18 22 89 90 0 5 0 4 7 0 0

0 0 0 426 22 0 14 0 0 3 1 15 0 4 0 0 0 1 0 100 34 12 0 3 13 61 71 218 1 6 0 26 0 0 0

0 0 0 305 15 0 12 0 0 3 0 14 6 2 0 0 0 1 0 100 26 7 0 3 8 39 64 149 0 4 0 54 0 0 0

0 0 6 814 83 0 46 0 0 10 14 36 44 18 0 0 0 14 0 271 143 34 2 12 75 169 378 604 1 17 0 87 7 0 0

0 0 0 33 63 0 18 0 0 14 9 1 21 6 0 0 0 14 0 42 27 13 1 5 19 47 151 273 0 2 0 1 0 0 0

0 0 0 62 82 0 49 0 1 17 10 25 22 5 0 0 0 1 1 42 75 8 1 10 22 28 153 262 0 2 0 5 0 0 0
 0 0 0 393 14 0 0 0 0 13 0 22 7 4 0 0 0 2 0 63 22 6 0 6 5 49 37 155 0 1 0 13 10 0 0

0 0 0 324 24 0 6 0 0 13 0 11 10 2 0 0 0 1 0 91 15 6 0 3 3 35 37 154 0 1 0 2 5 0 0

0 0 0 812 183 0 73 57 19 59 60 17 0 0 0 18 1 238 139 33 2 24 49 159 378 844 0 6 0 21 15 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

100%100%100%100%100%100%100%100%100%100%
100%
90%
80%
70%
60%
50%
40%
% Cum

30%
20%
10%
0 0 0 0 0 0 0 0 0
0%
E E /S IZE UT IZE IZE IZE FF
SIZ AG ER S O /S /S U/S R O
O/ AM ND . U/ ON O A. O . E
D U IA ITI H I IA W
AD GHT VE D OS E PT R D R D PO
E I P D NO O
R
HE R O O I AJ
M M
G
Rework

THICKNESS O/S
Step on face

OTHER
0 10 6

3 1 6

0 270 0

0 323 0

3 604 12

0 155 106

1 138 44

0 1761 0

0 1636 0

1 3690 150

0 127 88

0 127 52

0 1325 2

0 1666 27

0 3245 169

0 147 9

0 132 93
0 1190 19

0 1470 25

0 2939 146

0 0 0

0 0 0

0 0 0

0 0 0

0 0 0
 MACHINING REJECTION MONITORING SHEET
Machining Casting Rework Machining Defects

THREAD DAMAGE

HEIGHT UNDER/S
THREAD O/SIZE
THREAD U/SIZE

THICKNESS U/S

POSITION OUT

CHATTERING

CHAMFER NG
GROOVE DIA.
FACE/ID/OD

PROFILE NG
OD OVALITY

THICKNESS

ACCIDENT
DATE Part No. Total

SETTING
STEP ON

C.D OUT
Total Casting

OD.U/S

U/SIZE
TAPER
ID.O/S
Total Production Total Rej Qty Machining Total Rej Qty Total Rework
Rejection % Rework %
(Machining) (Machining) Rejection % (Casting) Qty
by qty
by Qty

1-Jan 1005724(R.H) 96 18 18.8% 15 15.6% 0 0.0% 1 5 9 2 1

2-Jan 1005724(R.H) 389 50 12.9% 33 8.5% 0 0.0% 10 16 1 9 2 4

3-Jan 1005724(R.H) 480 4 0.8% 51 10.6% 3 0.6% 2 1 1

4-Jan 1005724(R.H) 466 19 4.1% 86 18.5% 2 0.4% 9 7 1

5-Jan 1005724(R.H) 309 15 4.9% 69 22.3% 20 6.5% 7 5 1 1

6-Jan 1005724(R.H) 452 31 6.9% 17 3.8% 31 6.9% 6 20 1 2

7-Jan 1005724(R.H) 431 70 16.2% 38 8.8% 13 3.0% 6 16 10 16 5 4

8-Jan 1005724(R.H) 569 42 7.4% 99 17.4% 11 1.9% 1 2 2 1 31

9-Jan 1005724(R.H) 956 26 2.7% 206 21.5% 31 3.2% 1 3 1 13 7

10-Jan 1005724(R.H) 610 45 7.4% 42 6.9% 55 9.0% 14 11 10 6 1 1

11-Jan 1005724(R.H) 861 91 10.6% 49 5.7% 116 13.5% 5 25 10 11 2 22

12-Jan 1005724(R.H) 462 64 13.9% 41 8.9% 10 2.2% 4 2 26 8 5 14

13-Jan 1005724(R.H) 357 32 9.0% 37 10.4% 54 15.1% 4 1 1 18

14-Jan 1005724(R.H) 510 9 1.8% 39 7.6% 13 2.5% 2 3 1 1

15-Jan 1005724(R.H) 532 30 5.6% 69 13.0% 28 5.3% 7 1

16-Jan 1005724(R.H) 736 12 1.6% 91 12.4% 11 1.5% 2 6

17-Jan 1005724(R.H) 920 29 3.2% 78 8.5% 57 6.2% 3 6 12 1 2 1 1

18-Jan 1005724(R.H) 959 26 2.7% 24 2.5% 31 3.2% 1 5 1 10 1

19-Jan 1005724(R.H) 973 29 3.0% 110 11.3% 21 2.2% 4 11 2 6

20-Jan 1005724(R.H) 868 42 4.8% 44 5.1% 39 4.5% 4 13 1 4 3 9

21-Jan 1005724(R.H) 842 37 4.4% 69 8.2% 32 3.8% 9 10 2 7 1

22-Jan 1005724(R.H) 1016 28 2.8% 86 8.5% 40 3.9% 1 8 1 1 1

23-Jan 1005724(R.H) 853 32 3.8% 115 13.5% 27 3.2% 7 8 1 3 6

24-Jan 1005724(R.H) 1020 63 6.2% 108 10.6% 0 0.0% 9 17 14 3

25-Jan 1005724(R.H) 1067 25 2.3% 104 9.7% 18 1.7% 12 2 6 1 1 1

26-Jan 1005724(R.H) 477 6 1.3% 13 2.7% 0 0.0% 1 1 1 1 1

27-Jan 1005724(R.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

28-Jan 1005724(R.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

29-Jan 1005724(R.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

30-Jan 1005724(R.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

31-Jan 1005724(R.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

17211 875 5.1% 1733 10.1% 663 3.9% 70 1 0 0 0 0 18 6 182 145 0 86 0 0 63 20 15 99

0.4% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 1.1% 0.8% 0.0% 0.5% 0.0% 0.0% 0.4% 0.1% 0.6%

0
ID.O /S
 Casting Defects after machining Rework Casting Defects In Casting

MAJOR DIA.U/SIZE

EXTRA MATERIAL

EXTRA MATERIAL
SAND INCLUSION

SAND INCLUSION

PARTTING LINE
THICKNESS O/S
FACE UNCLEAN

THICKNESS NG
TOOL BROKEN

PARTING LINE
DEPTH O/SIZE

Step on face
BLOW HOLE

SAND WASH
PROFILE NG
POWER OFF

SHRINKAGE
DIA.O/SIZE

Height NG

PATTERN

PIN HOLE
LEAKAGE

BROKEN
DIA. U/S

DIA. U/S
OTHERS

DIA.O/S
OTHER

OTHER
MINOR

CRACK

BULGE

BEND
DENT

DENT

DENT

DENT
SLAG

SLAG

SLAG
1 1 6 2 5

2 6 4 10 8 1 10

8 4 7 3 26 3 3

2 10 1 38 4 5 28 2

1 7 2 51 1 2 5 1 9 5 6

2 1 1 1 14 5 24 2

2 1 10 9 1 6 1 20 1 13

1 4 2 5 3 3 63 23 11

1 10 1 13 10 158 14 1 20 10

2 7 1 5 2 22 5 2 53

4 12 2 2 37 8 83 33

5 1 7 5 28 2 8

2 2 4 8 1 1 4 8 12 1 2 39 15

1 1 2 2 1 4 8 9 12 1 9 4

22 5 1 10 1 32 19 1 13 15

1 2 1 2 1 2 17 46 23 7 4

2 1 12 1 1 6 4 24 30 39 18

8 6 8 10 3 28

5 1 10 2 1 12 9 35 41 17 4

4 4 2 2 3 17 19 1 39

8 5 2 12 24 26 32

1 5 10 8 2 1 2 1 15 28 28 1 40

2 5 10 2 10 12 27 54 27

2 4 14 3 3 1 5 2 29 65
 1 1 1 1 3 3 14 81 1 9 9

1 1 12

26 0 0 0 25 0 119 131 25 10 12 190 142 604 606 0 5 0 8 15 0 0 0 439 209 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0.2% 0.0% 0.0% 0.0% 0.1% 0.0% 0.7% 0.8% 0.1% 0.1% 0.1% 1.1% 0.8% 3.5% 3.5% 0.0% 0.0% 0.0% 0.0% 0.1% 0.0% 0.0% 1.2% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
 Casting Defects In Casting

SHRINKAGE

COLD RUN

CRACK

CUTTING

E XCESS GRINDING

LOGO MISSING
(P1)

FATTELING

OTHER
 0 0 0 0 0 0 0 0

0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%

 MACHINING REJECTION MONITORING SHEET
Machining Casting Rework Machining Defects

THREAD DAMAGE

HEIGHT UNDER/S
THREAD O/SIZE
THREAD U/SIZE

THICKNESS U/S

POSITION OUT

CHATTERING

CHAMFER NG
GROOVE DIA.
FACE/ID/OD

PROFILE NG
OD OVALITY

THICKNESS

ACCIDENT
DATE Part No. Total

SETTING
STEP ON

C.D OUT
Total Casting

OD.U/S

U/SIZE
TAPER
ID.O/S
Total Production Total Rej Qty Machining Total Rej Qty Total Rework
Rejection % Rework %
(Machining) (Machining) Rejection % (Casting) Qty
by qty
by Qty

1-Jan 1005724(L.H) 125 5 4.0% 12 9.6% 0 0.0% 1 1

2-Jan 1005724(L.H) 264 31 11.7% 9 3.4% 0 0.0% 22 9

3-Jan 1005724(L.H) 497 20 4.0% 85 17.1% 0 0.0% 2 11 5

4-Jan 1005724(L.H) 476 15 3.2% 47 9.9% 0 0.0% 3 4 3

5-Jan 1005724(L.H) 333 39 11.7% 62 18.6% 26 7.8% 14 1 1 6 5 1 7

6-Jan 1005724(L.H) 516 25 4.8% 24 4.7% 4 0.8% 1 3 2 17

7-Jan 1005724(L.H) 417 18 4.3% 30 7.2% 15 3.6% 1 5 1 3 5

8-Jan 1005724(L.H) 466 25 5.4% 68 14.6% 25 5.4% 17 3

9-Jan 1005724(L.H) 453 25 5.5% 12 2.6% 10 2.2% 4 2 4 3 6 2

10-Jan 1005724(L.H) 711 36 5.1% 57 8.0% 41 5.8% 19 3 3 1

11-Jan 1005724(L.H) 706 56 7.9% 61 8.6% 35 5.0% 4 1 15 7 15 2 5 1

12-Jan 1005724(L.H) 493 35 7.1% 45 9.1% 28 5.7% 20 6

13-Jan 1005724(L.H) 535 14 2.6% 37 6.9% 46 8.6% 4 1 2 1

14-Jan 1005724(L.H) 482 17 3.5% 28 5.8% 12 2.5% 5 4 3 1 2 2

15-Jan 1005724(L.H) 506 15 3.0% 33 6.5% 23 4.5% 7 1 1

16-Jan 1005724(L.H) 524 17 3.2% 37 7.1% 2 0.4% 5 4 6 1

17-Jan 1005724(L.H) 507 20 3.9% 37 7.3% 3 0.6% 8 3 1 4

18-Jan 1005724(L.H) 791 35 4.4% 39 4.9% 63 8.0% 2 7 5 1 2 5

19-Jan 1005724(L.H) 847 44 5.2% 64 7.6% 37 4.4% 14 9 3 2 4

20-Jan 1005724(L.H) 921 38 4.1% 63 6.8% 43 4.7% 3 6 14 7 1 2

21-Jan 1005724(L.H) 949 61 6.4% 94 9.9% 23 2.4% 13 15 1 2 9 15

22-Jan 1005724(L.H) 924 42 4.5% 47 5.1% 39 4.2% 14 9 2 2 1 4 5

23-Jan 1005724(L.H) 968 65 6.7% 111 11.5% 64 6.6% 12 11 8 1 6 4 8 1

24-Jan 1005724(L.H) 861 75 8.7% 108 12.5% 0 0.0% 2 13 27 13 2 1 2 1

25-Jan 1005724(L.H) 1035 27 2.6% 94 9.1% 56 5.4% 8 4 5 8

26-Jan 1005724(L.H) 502 22 4.4% 49 9.8% 0 0.0% 6 9 3 1

27-Jan 1005724(L.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

28-Jan 1005724(L.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

29-Jan 1005724(L.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

30-Jan 1005724(L.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

31-Jan 1005724(L.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

15809 822 5.2% 1353 8.6% 595 3.8% 46 1 0 0 0 0 35 0 168 158 0 104 0 4 36 21 69 36

0.3% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 1.1% 1.0% 0.0% 0.7% 0.0% 0.0% 0.2% 0.4% 0.2%

0
ID.O /S
Machining Defects Casting Defects after machining Rework

SAND INCLUSION

THICKNESS O/S
FACE UNCLEAN

THICKNESS NG
TOOL BROKEN
DEPTH O/SIZE

Step on face
BLOW HOLE

PROFILE NG
POWER OFF

SHRINKAGE
DIA.O/SIZE

DIA.U/SIZE

MATERIAL

Height NG

DIA. U/S
OTHERS

OTHER

OTHER
MINOR

MAJOR

EXTRA
CRACK

SLAGE
DENT

DENT

DENT
SLAG
3 4 4 4

2 1 3 2 1

2 10 2 5 4 41 20 3

5 8 3 14 2 2 18

4 5 1 45 4 6 1 16 3 1 6

2 3 1 2 1 16 1 1 1 1 1

3 7 4 1 2 13 3 6 9

1 4 2 3 4 6 1 33 19 4 21

1 3 3 2 2 2 11 40 7 2 1 36

2 8 2 3 2 2 31 17 28 13

1 5 1 2 1 6 47 4 35

9 1 3 3 21 17 28

2 4 3 1 1 20 9 3 46

2 1 1 1 6 6 10 . 1 12

1 5 5 3 4 9 11 1 7 12 4

1 5 2 2 15 12 1 2

1 3 5 8 3 11 10 1 2

1 12 1 2 4 6 11 12 . 3 19 44

2 10 17 2 1 1 17 26 35 2

1 4 1 1 2 11 38 10 11 32

1 5 28 19 47 16 7

1 4 1 4 2 4 17 18 1 39

3 11 19 1 3 4 13 22 48 1 64

14 15 2 4 6 30 51
 1 1 4 3 3 5 11 64 4 2 54

3 7 1 16 24 1

31 0 0 0 5 1 107 161 27 13 11 125 87 464 495 0 9 0 18 25 0 0 195

0.2% 0.0% 0.0% 0.0% 0.0% 0.0% 0.7% 1.0% 0.2% 0.1% 0.1% 0.8% 0.6% 2.9% 3.1% 0.0% 0.1% 0.0% 0.1% 0.2% 0.0% 0.0% 1.2%

0
ID.O /S
 MACHINING REJECTION MONITORING SHEET
Machining Casting Rework Machining Defects

THREAD DAMAGE

HEIGHT UNDER/S
THREAD O/SIZE
THREAD U/SIZE

THICKNESS U/S

POSITION OUT

CHATTERING

CHAMFER NG
GROOVE DIA.
FACE/ID/OD

PROFILE NG
OD OVALITY

THICKNESS

ACCIDENT
DATE Part No. Total

SETTING
STEP ON

C.D OUT
Total Casting

OD.U/S

U/SIZE
TAPER
ID.O/S
Total Production Total Rej Qty Machining Total Rej Qty Total Rework
Rejection % Rework %
(Machining) (Machining) Rejection % (Casting) Qty
by qty
by Qty

1-Jan 1005789(R.H) 189 51 27.0% 27 14.3% 20 10.6% 2 29 14 5

2-Jan 1005789(R.H) 482 42 8.7% 39 8.1% 28 5.8% 19 3 1 3

3-Jan 1005789(R.H) 487 74 15.2% 35 7.2% 57 11.7% 32 3 7 8

4-Jan 1005789(R.H) 629 92 14.6% 66 10.5% 76 12.1% 42 5 4 16

5-Jan 1005789(R.H) 584 127 21.7% 42 7.2% 89 15.2% 6 17 35 4 13 4

6-Jan 1005789(R.H) 885 73 8.2% 56 6.3% 234 26.4% 12 54 5 1 1

7-Jan 1005789(R.H) 714 60 8.4% 32 4.5% 199 27.9% 6 22 5 3 4 4 2

8-Jan 1005789(R.H) 917 63 6.9% 0 0.0% 189 20.6% 45 8 2 2 1

9-Jan 1005789(R.H) 926 68 7.3% 5 0.5% 10 1.1% 5 14 36 7 3

10-Jan 1005789(R.H) 848 95 11.2% 84 9.9% 298 35.1% 71 7 7 1 1

11-Jan 1005789(R.H) 828 100 12.1% 60 7.2% 317 38.3% 9 51 4 3 13 1

12-Jan 1005789(R.H) 768 69 9.0% 45 5.9% 178 23.2% 3 51 2 4 8

13-Jan 1005789(R.H) 871 83 9.5% 42 4.8% 187 21.5% 3 1 70 3

14-Jan 1005789(R.H) 932 67 7.2% 67 7.2% 208 22.3% 59 5 1

15-Jan 1005789(R.H) 939 112 11.9% 76 8.1% 193 20.6% 77 1

16-Jan 1005789(R.H) 950 77 8.1% 68 7.2% 180 18.9% 1 49 10 8

17-Jan 1005789(R.H) 948 102 10.8% 60 6.3% 160 16.9% 68 1 4 1

18-Jan 1005789(R.H) 939 84 8.9% 91 9.7% 180 19.2% 60 3

19-Jan 1005789(R.H) 836 66 7.9% 41 4.9% 219 26.2% 43 2 3 13

20-Jan 1005789(R.H) 918 60 6.5% 48 5.2% 232 25.3% 46 2 8

21-Jan 1005789(R.H) 928 93 10.0% 45 4.8% 234 25.2% 2 64 7 2

22-Jan 1005789(R.H) 902 63 7.0% 38 4.2% 169 18.7% 46 6 1 2

23-Jan 1005789(R.H) 873 106 12.1% 52 6.0% 135 15.5% 79 1 4

24-Jan 1005789(R.H) 927 76 8.2% 49 5.3% 203 21.9% 60 3 1 3

25-Jan 1005789(R.H) 939 88 9.4% 35 3.7% 169 18.0% 72 2 3 8

26-Jan 1005789(R.H) 473 34 7.2% 27 5.7% 77 16.3% 26 1 2

27-Jan 1005789(R.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

28-Jan 1005789(R.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

29-Jan 1005789(R.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

30-Jan 1005789(R.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

31-Jan 1005789(R.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

20632 2025 9.8% 1230 6.0% 4241 20.6% 31 1 0 0 0 0 78 0 1291 87 0 52 0 1 63 1 71 11

0.2% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 6.3% 0.4% 0.0% 0.3% 0.0% 0.0% 0.3% 0.0% 0.1%

0
ID.O /S
Machining Defects Casting Defects after machining Rework

MAJOR DIA.U/SIZE

EXTRA MATERIAL
SAND INCLUSION

THICKNESS O/S
FACE UNCLEAN

THICKNESS NG
TOOL BROKEN
DEPTH O/SIZE

Step on face
BLOW HOLE

PROFILE NG
POWER OFF

SHRINKAGE
DIA.O/SIZE

Height NG

DIA. U/S
OTHERS

OTHER

OTHER
MINOR

CRACK
DENT

DENT

DENT
SLAG

SLAG
1 2 1 4 5 8 4 3 20

3 13 1 1 5 13 15 4 28

24 9 2 1 6 7 9 1 57

2 23 7 1 4 7 3 40 3 1 76

48 8 2 1 10 11 8 2 89

2 2 1 8 4 13 8 18 234

14 6 6 15 5 199

5 189

2 1 2 2 4 1 5 39 14 6 346

3 5 2 1 1 7 6 33 31 3 298

19 5 1 10 8 18 5 13 317

1 3 1 1 5 5 17 13 178

6 3 2 2 22 1 12 187

1 1 1 3 4 10 9 33 1 6 208

1 33 8 3 9 17 38 1 193

1 8 1 2 2 3 13 20 25 2 180

28 6 1 2 9 10 31 1 160

1 20 11 1 4 20 8 42 1 4 178 2

1 4 4 1 5 27 4 219

1 3 1 1 3 1 5 14 20 3 232

1 1 16 3 2 12 4 21 3 2 226 6

1 7 2 2 5 6 21 1 1 8 154 7

22 6 2 1 10 4 23 6 135

1 8 7 1 2 7 6 26 197 6
 1 2 1 2 10 3 19 169

5 2 25 77

16 0 0 0 5 0 317 101 31 6 10 28 183 209 563 1 62 0 104 10 0 0 0 4546 21

0.1% 0.0% 0.0% 0.0% 0.0% 0.0% 1.5% 0.5% 0.2% 0.0% 0.0% 0.1% 0.9% 1.0% 2.7% 0.0% 0.3% 0.0% 0.5% 0.0% 0.0% 0.0% 0.1%

0
ID.O /S
 MACHINING REJECTION MONITORING SHEET
Machining Casting Rework Machining Defects

THREAD DAMAGE

HEIGHT UNDER/S
THREAD O/SIZE
THREAD U/SIZE

THICKNESS U/S

POSITION OUT

CHATTERING

CHAMFER NG
GROOVE DIA.
FACE/ID/OD

PROFILE NG
OD OVALITY

THICKNESS

ACCIDENT
DATE Part No. Total

SETTING
STEP ON

C.D OUT
Total Casting

OD.U/S

U/SIZE
TAPER
ID.O/S
Total Production Total Rej Qty Machining Total Rej Qty Total Rework
Rejection % Rework %
(Machining) (Machining) Rejection % (Casting) Qty
by qty
by Qty

1-Jan 1005789(L.H) 189 22 11.6% 19 10.1% 16 8.5% 22

2-Jan 1005789(L.H) 482 29 6.0% 27 5.6% 65 13.5% 2 20 2 1 1

3-Jan 1005789(L.H) 487 76 15.6% 48 9.9% 79 16.2% 1 32 1 22 11

4-Jan 1005789(L.H) 629 106 16.9% 68 10.8% 69 11.0% 3 57 5 19 11 1

5-Jan 1005789(L.H) 584 87 14.9% 65 11.1% 94 16.1% 3 8 33 8 8 4

6-Jan 1005789(L.H) 885 88 9.9% 66 7.5% 203 22.9% 8 66 1 1 5 1

7-Jan 1005789(L.H) 714 93 13.0% 69 9.7% 216 30.3% 65 5 2 4 2 2

8-Jan 1005789(L.H) 917 69 7.5% 49 5.3% 190 20.7% 47 2 5 2

9-Jan 1005789(L.H) 926 94 10.2% 81 8.7% 270 29.2% 26 59 3

10-Jan 1005789(L.H) 848 106 12.5% 89 10.5% 289 34.1% 84 3 9 1

11-Jan 1005789(L.H) 828 86 10.4% 49 5.9% 258 31.2% 57 5 3 14 3

12-Jan 1005789(L.H) 768 74 9.6% 39 5.1% 213 27.7% 2 52 1 3 4 2

13-Jan 1005789(L.H) 871 54 6.2% 47 5.4% 321 36.9% 1 42 1 2

14-Jan 1005789(L.H) 932 17 1.8% 71 7.6% 228 24.5% 1 7 2 5

15-Jan 1005789(L.H) 939 77 8.2% 78 8.3% 228 24.3% 41 2 5 2 2

16-Jan 1005789(L.H) 950 79 8.3% 45 4.7% 220 23.2% 1 61 3 5 1

17-Jan 1005789(L.H) 948 72 7.6% 53 5.6% 226 23.8% 55 1 2

18-Jan 1005789(L.H) 939 107 11.4% 36 3.8% 240 25.6% 2 66 5 1 4

19-Jan 1005789(L.H) 836 57 6.8% 24 2.9% 230 27.5% 33 1 3 3

20-Jan 1005789(L.H) 918 93 10.1% 23 2.5% 278 30.3% 2 46 5 4 2

21-Jan 1005789(L.H) 928 104 11.2% 39 4.2% 295 31.8% 2 56 4 8 3 4

22-Jan 1005789(L.H) 902 62 6.9% 48 5.3% 225 24.9% 46 2 2 3 1 2

23-Jan 1005789(L.H) 873 70 8.0% 53 6.1% 248 28.4% 51 6 1 1 4

24-Jan 1005789(L.H) 927 60 6.5% 48 5.2% 219 23.6% 52 4

25-Jan 1005789(L.H) 939 51 5.4% 28 3.0% 151 16.1% 42 3 1 4

26-Jan 1005789(L.H) 473 46 9.7% 17 3.6% 84 17.8% 31

27-Jan 1005789(L.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

28-Jan 1005789(L.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

29-Jan 1005789(L.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

30-Jan 1005789(L.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

31-Jan 1005789(L.H) 0 #DIV/0! 0 #DIV/0! 0 #DIV/0!

20632 1879 9.1% 1279 6.2% 5155 25.0% 18 2 0 0 0 0 42 0 1223 75 0 75 0 0 65 0 57 19

0.1% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 5.9% 0.4% 0.0% 0.4% 0.0% 0.0% 0.3% 0.0% 0.1%

0
ID.O /S
Machining Defects Casting Defects after machining Rework

EXTRA MATERIAL
SAND INCLUSION

THICKNESS O/S
FACE UNCLEAN

THICKNESS NG
TOOL BROKEN
DEPTH O/SIZE

Step on face
BLOW HOLE

PROFILE NG
POWER OFF

SHRINKAGE
DIA.O/SIZE

DIA.U/SIZE

Height NG

DIA. U/S
OTHERS

OTHER

OTHER
MINOR

MAJOR

CRACK
DENT

DENT

DENT
SLAG

SLAG
1 1 3 4 9 1 16

2 1 2 8 17 65

2 7 5 1 6 9 22 5 79

10 5 1 4 8 5 30 15 69

2 21 6 5 10 11 8 10 15 94

2 4 4 1 1 10 11 10 2 27 3 200

13 4 3 2 7 3 21 2 27 216

13 1 12 34 1 1 190

1 2 3 3 1 3 6 43 12 1 12 270

9 1 5 9 35 13 26 289

4 2 1 4 9 20 1 12 258

10 1 2 22 14 213

8 8 1 3 26 9 321

2 2 2 1 4 8 26 28 228

1 24 9 1 1 13 36 2 16 228

1 7 2 17 12 13 1 199 21

14 4 4 9 18 18 226

29 1 3 2 9 6 13 1 1 240

1 16 2 1 4 17 224 6

34 10 13 278

1 26 1 2 1 11 6 17 1 5 270 20

6 2 2 6 6 32 220 5

1 6 7 1 2 4 7 30 1 1 248

1 3 2 12 7 27 219
 1 5 2 1 20 151

15 2 15 84

11 0 0 0 6 0 286 65 28 8 6 33 144 214 545 0 25 0 211 8 0 0 0 5095 52

0.1% 0.0% 0.0% 0.0% 0.0% 0.0% 1.4% 0.3% 0.1% 0.0% 0.0% 0.2% 0.7% 1.0% 2.6% 0.0% 0.1% 0.0% 1.0% 0.0% 0.0% 0.0% 0.3%

0
ID.O /S