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									An Amrep Company Date :May 27 to May 31(5 day) Attn: Brain Williams; David Kaminski Cc: Lawrence; Mona; Kennedy Fr: Jimmy Zhang S/N Descirption Day 1 Short meeting with Mr Dave kamon

PRC office: Tel.86 (755)27834426/526 Fax no.86 (755) 27800822 HK office: Tel.(852) 2602 6879 Fax no.(852) 2602 7612

Problem

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Suggestion or status

1

Yesterday evening,Mr Dave Kamon,Jimmy sun and I had a short meeting from 10:30 pm to 11.10 pm .we introduced each other , discussed about the 8D report and detailed schedule.Jimmy sun proposed a more important problem that is DFF want to know how high hardness of the rejected products delivered when I was at the DFF first time. In this morning,from 9:00 am to 10:00 am,Dave Kamon,Jimmy sun ,I had a short meeting with the people from DFF including sales department,R&D department,Manufacturing department,and Quality department,totally 8 people

28-May

In this morning,Mr Dave Kamon said it's from HR 31 to HR 35 .

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Short meeting with DFF

28-May

DFF has a brief introduce to Mr Dave,DFF thought when we get more information and find some problem after review the process,we will have a meeting again.

3

visit the whole process

we visited the die making workshop---test lab--forging workshop---heat treatment department--magnetic detect workshop --- caliration plant---shot blasting plant.

28-May

4

the run status

3.1 DFF had the upset forging yesterday on B42027F with 130 pcs,B42028-F with 140 pcs,and all the material of the B42026-F already finished the shearing process.

28-May

S/N Descirption

Problem 3.2 They are performing the final forging of B42026F now,as some trouble occuring on the oil press machine and the die of the B42026-F that is a new die.the problem is a small padding bar is too long so that the location pin is not available when they are forging.After repairing,the die and the machine are both available till 11:30 PM.

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Suggestion or status It wasted a whole day to repair the oil press machine and the new die.I have proposed to DFF that it's not available and reasonable of the operating method .DFF should have a review when they finish the tool and the die to check if their tools and die are available.But as far as I know,till now,there is any action to improve it.

3.3 DFF had a dimension check of the first 5 parts according to the QP at 12:00 PM,after checking ,the result is ok then they were informed they can continue to run the rest.tonight,they will complete the B42026-F and B42027-F,as for the B42028-F maybe in the tomorrow morning.

28-May

30-May

DFF just forged 300 pcs of B42026-F,As for B42027-F and B42028-F,they didn't run it normally.

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Sample size of dimensional check

As requested by Mr Dave Kamon,I will handle a dimension check when they finish all process including 3 pcs before H.T and 3 pcs after H.T for B42026-F and B42027-F,as for the B42028F,check 6 pcs without H.T.

28-May

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H.T of B42028-F

DFF said there is no way to run the whole heat treatment line just for only ten pcs,so for this time ,they still don't want to perform the H.T for B42028F,as for B42026-F and B42027-F ,they will

28-May

7

Part marking

there is a mistake occuring on the Part Marking of B42026-F as they used the material that was used to re-sized for last time.they used the number "556" instead of "142",

28-May

After discussing with Mr Dave Kamon who agreed and asked DFF to add a big dot on the die to distinguish the Part Marking form different furnace number! then they were informed that they can continue to run .As for the B42027-F and B42028-F, .they uesed the latest material that both come from Fushun steel ,so it's available!

S/N Descirption Day 2 1 Run status

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DFF forged 300 pcs of B42026-F yesterday evening, and run to the magnetic detect process at 5:00 pm today, but as for the B42027-F was not forged according to initial plan, when we arrived at their workshop, we found the operators didn’t run any more as there is some thing wrong of the sensor. The I.D of the sensor is just designed for the last time that all of the material need to be re-rezing, so when they used the latest material, after upset forging, the diameter is out of spec so it leads that it’s very difficult to put the part into the sensor to heating, till 4:30 pm they have repaired the sensor to enlarge the I.D of the sensor and added a block at the bottom., at 5:00 pm, they forged 5 pcs to check the dimension according to QP, about 9:30 they finished the dimension check just for the first 5 pcs. It’s said that they will forge the B42027-F and B42028-F tonight, tomorrow morning can start to take H.T process. as for if it’s true, waiting for our review tomorrow morning.

29-May

The same problem happened on the die or tool as I mentioned yesterday,at the same time,we can see that the problem-solving efficiency and reaction of DFF is not available. That's the reason why the progress often delay during manufacturing process.

2

TS’s problem

when we review their process at the forging workshop, we found the SOP used at the site isn’t tally with QP including missing some items ,some of items don’t define clearly, using wrong way to measure , for example, they used the visual instead of the caliper when they measured the item ”mismatch” as they do the first 5 pcs check, and also the records are not available. We will discuss this problem with their engineer tomorrow morning.

29-May

suggest DFF must perfom the check at every procedure according to the QP and SOP including the records

3

The final dimensional check and shipment date

Due to delay of the production, I will have less than one day to check the dimension .All of the parts maybe can be delivered on June 2 or June 3,About the details will discuss with Mr Wu Dun tomorrow.Tomorrow,I will handle the final dimensional check ,maybe it will take an half of day on May 31 to measure

29-May

It was said that it will be delivered on June 2

S/N Descirption Day 3 1 run status

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Suggestion or status

DFF had forged all of the parts for three part number before I arrived at DFF this morning.DFF finished the H.T process of B42026-F in this morning! As for the B42027-F,at 12:00 am,then DFF started to the H.T process,tonight,DFF would finish the H.T process.The parts that don't need do the H.T process is performed the cutting process,but the parts are not performed the M.P.I and shot blasting process till now

30-May

But the parts were not performed the cutting process as there was something wrong on the crane at the site.

2

Dimensional check

As requested by Mr Dave Kamon,I performed the dimensional check 3 pcs of B42026-F ,the details pls refer to the attached file,at the same time,tomorrow,I will handle the dimensional check 3 pcs for B42027-F and B42028-F requested by Mr Dave Kamon As requested by Mr Dave Kamon,DFF need submit 30-May the 8D report and new QP,FMEA,process flow diagram again.

30-May

The result is ok.

3

8 D report and PPA issue

waiting for submission from DFF

Day(4) 1 Delayed the cutting process 1.1 Yesterday evening,the parts were not performed 31-May the cutting process accordingly as there is something wrong on the crane at the site in the whole evening.till 11:00 am today,DFF just started this process under my strong press. 1.2 There is no SOP at the site,and I asked the operators how to handle it ,and the operators said because there are too many kinds of products,they didn't familiar with this product . 2 Dimensional check As requested by Mr Dave Kamon,took 3 pcs for dimensional check for B42027-F and B42028-F 31-May Mr Wu Dun (sales person from DFF) said it would finish the cutting process this afternoon.

I think DFF should have an action to make a improvement of the T/S

31-May

the result is ok

3

shipment date

it was said that it would be ship the parts on June 2 31-May

Prepared by: Jimmy & Kennedy Dated by:31 May 2007 Critical item, need advise Open item Close item

Prepared by: Jimmy & Kennedy Dated by:7 May 2007 Critical item, need advise Open item Close item


								
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