Sr. No. Issue Description Responsible Dept.
PV of Main temperature controller and Over temperature Controller
1 Wesman engineer
Veriates by 50℃
2 Loader car joystick is not available for operation. Wesman engineer
3 Uniloader arm not functioning at the roller table (for unloading). Wesman engineer
4 Quench oil level is not given (minimum/max ) Wesman engineer
5
Furnace brick quality is poor; cracks observed.(observed crack in pre-
heating,SQF 1, SQF 2 , Tempering ) Wesman engineer
6 Washing machine is not cleaning materials effectively. Wesman engineer
7 Excess soot formation in SQF-2 furnace. Wesman engineer
8 ENDO furnace millivolt not available. Wesman engineer
9 PV dew point is rising than SV unusually, no alarm triggered. Wesman engineer
10
Tempering thermocouple not adjusted properly, creating noise during
unloading. Wesman engineer
11 Furnace indicator sometimes gives false signal. Wesman engineer
12
Endo Generator 2 showing reddish discoloration on the body of heating
chamber trial. Wesman engineer
14 Pre-heating RC fan belt is broken. Currently running on a single belt. Wesman engineer
15 Pre-heating Alarm buzzer is not working Properly. Wesman engineer
16 SQF 1 chain Making unusual sound during Quenching Wesman engineer
17 Charge Car/ Loader Limit broke by mannually pushing charge . Wesman engineer
18 Muffle of the furnaces do not have TUS Whole in it Wesman engineer
19
If TUS whole is given it do not have proper alignment with the TUS point
of furnace body Wesman engineer
20 2nd oxy probe not in functional in all SQF furnace Wesman engineer
21 Washing machine one heater is in open condition Wesman engineer
22 Extra switch installed on endo line beside furnace gas line Wesman engineer
23 Water level gauge of post-washing furnace not working Wesman engineer
24 Loader misaligned with table rollers, obstructing movement of charge Wesman engineer
25 Rear door leakage in SQF-2
26 Mismatch in CP controller and CP indicator values Wesman engineer
27 Cracks in brick lining of Pre-heating, Tempering, and SQF furnaces Wesman engineer
28 Rear door leakage in SQF-3 during quenching
29 Endo selector switch working operation is different in both units Wesman engineer
30 SQF-2 has copper pressure line; SQF-1 & SQF-3 have plastic Wesman engineer
31 All hooters not working properly Wesman engineer
32 Abnormal sound from SQF-2 during quenching Wesman engineer
Wesman Issues
Actual
Opening Expected
Closing Action Requirement
Date closing date
Date
03.03.2025 20.05.2025 Replacement of thermocouple and calibration required.
01.04.2025 18.05.2025 Required to fix joystick ASAP for smooth operation
01.03.2025 - 28.04.2025
15.03.2025 28.04.2025 Provide minimum and maximum level markings
for quench oil tank.
20.03.2025 25.05.2025 Replace cracked furnace bricks and inspect for
further damages.
Investigate and resolve ineffective washing machine
16.04.2025 30.04.2025 operation.
16.04.2025 29.04.2025 28.04.2025 Identify root cause for soot formation in SQF-2 furnace.
10.03.2025 Provide working millivolt output for ENDO furnace sensors.
10.03.2025 Investigate unusual PV rise and ensure alarm functionality.
Adjust and secure tempering thermocouple to eliminate
10.03.2025 16/04/2025 noise.
Check and correct furnace indicator to eliminate false
01.04.2025 signals.
Inspect reddish discoloration on Endo Generator 2 and
22.04.2025 determine cause.
22.04.2025 Replace broken pre-heating RC fan belt immediately.
24.04.2025 03.05.2025 Rectify pre-heating alarm buzzer malfunction.
Investigate and resolve the unusual sound
24.04.2025 29.04.2025 coming from the SQF 1 chain during quenching
operation.
Repair or replace the broken Charge Car/Loader limit switch
20.03.2025 03.05.2025 damaged by manual pushing.
Modify the muffles of the furnaces to
01.03.2025 incorporate TUS (Temperature Uniformity
Survey) holes as per standard requirements.
Realign the TUS hole positioning to ensure
01.03.2025 proper alignment with the furnace body
measuring points.
01.03.2025 installation pending
01.06.2025 wesman
Review the installation. Remove or relocate the
extra switch if it's not as per safety or
operational standards. Ensure compliance with
electrical safety norms.
Inspect and replace or repair the faulty water level gauge to
ensure proper monitoring of water levels.
Realign the loader and table rollers properly to
allow smooth and unhindered movement of the
charge. Check for any mechanical damage.
Inspect door gasket/seals. Replace if worn out
or damaged. Check and adjust locking
mechanisms for proper sealing.
Calibrate the carbon potential controller and the CP
indicator. Verify sensor accuracy and replace if faulty.
Conduct detailed inspection of furnace lining.
Repair or replace the damaged refractory bricks
as needed to prevent heat loss and safety
hazards.
Inspect and repair rear door sealing. Ensure
quenching system does not cause pressure
buildup beyond design limits.
Standardize the wiring and configuration of the selector
switches. reprogram to ensure consistent functioning across
units.
Review material compatibility. Standardize all
pressure lines using the most suitable and safe
material.
Inspect the hooter system's power supply and
control wiring. Replace defective hooters and
test alarm functionality.
Inspect quenching mechanism for mechanical faults or loose
components. Lubricate or replace parts as needed.
Action Taken Status Remarks
Wesman planned for changing
thermocouple with new one done
Temporary operation enabled by placing
a manual switch in loader. done
According to wesman
engineer ,uniloader will work only in Done
front of furnaces.
Quench oil levels marked and
standardized. Done
Temporary patch done; bricks sent for
quality inspection. Pending Bricks are sent for the quality check .
Issue escalated to Wesman; Wesman suggested to use skimmer
(as per wesman suggestion we used
skimmer use suggested for Pending skimmer while process but still material
improvement. not cleaned properly)
Trial conducted; no soot
Trial Taken ( no soot found )
formation detected. Monitoring Done Under observation
continued.
Issue raised with Wesman; Once both endo are in runnnng wesman
Pending will fix it
awaiting corrective action.
LPG flow variation detected;
LPG flow is not proper causing veriation in
Wesman recommendation done PV and Sv suggested by wesman
implemented.
Thermocouple adjusted and Done
noise issue resolved.
Issue communicated to Wesman; Pending Reset required
reset required.
Awaiting Wesman’s feedback
regarding heating chamber done Pending from wesman side
reaction.
New belt required; replacement
pending to prevent further done New belt required for proper fixing.
damage.
Wesman informed for necessary done
repairs.
Issue informed to Wesman engineer done
for inspection and corrective action.
Limit switch repaired by Wesman
engineer; normal operation restored. Done Support will be provided in loader
Issue under review; necessary done
modifications to be planned.
Issue under review; alignment
correction to be addressed during Pending
modification.
pending
inform to wesman Pending
Shop floor issue a
Responsible
Sr. No. Issue Description Opening Date
Dept.
bearing cup rack is needed to organize and
1
store green materials properly.
A forklift is required for safe and efficient
2
movement of materials.
A crane is needed in the machine shop for
3
lifting and unloading heavy parts.
PPE kits must be provided to ensure worker
4
safety.
A first aid kit is required in the SACPL area for
5
emergency response.
The lifter pallet chain needs proper
6
oiling/greasing for smooth operation.
Two wall fans are needed to improve air
7 circulation and material cooling in the shop
and machining area.
Machines do not have identification tags, which
8
can affect traceability and safety.
There is water seepage in the SQF pit that
9
needs to be fixed to avoid damage.
Process tags and a logbook required affecting
10
proper process tracking.
A surface table is needed in the SACPL
11
machining area.
The RH3 front door glass is broken and should
12
be replaced for safety.
Furnace paint is peeling off and needs
13
repainting to maintain protection.
The sieving frequency of blasting shots is not
14
fixed, affecting quality.
Babri movement is delayed, causing items to
15
fall on the floor.
The AC gas needs checking and possible
16
refilling to restore cooling.
AC and TV backboards need repainting for
17
better appearance.
The vaporizer filter and water system require
18
proper cleaning.
An extra roller table is needed for extra charge
19
rest point without hindering process.
hop floor issue and improvement
Expected Actual
Action Requirement Action Taken
closing date Closing Date
Need to purchase bearing cup rack for proper
and safe storage of green materials.
Arrange for a forklift to ensure safe and efficient
movement and loading of materials.
Install or provide a crane in the machine shop
for safe handling of heavy components.
Provide complete Personal Protective Equipment
kits to all relevant employees.
Ensure a fully equipped first aid kit is made
available in the SACPL area.
Perform preventive maintenance by
oiling/greasing the chain of the lifter pallet.
Need to install two wall-mounted fans to improve
ventilation and comfort in the shop floor and
machining areas.
Attach proper identification and safety tags on
all machines. Ensure tag management system is
implemented.
Investigate and repair the cause of seepage in
the SQF pit to prevent structural or safety
issues.
Introduce and maintain process logbooks and
tagging systems for tracking operations.
Install a surface table in the machining area to
support precise inspection and operations.
Replace the broken front glass of RH3 to restore
safety and equipment integrity.
Repaint the furnace using high-temperature-
resistant paint to maintain insulation and
protection.
Define and standardize sieving frequency for
shot blasting shots to maintain blasting quality.
Review and optimize babri movement timing.
Repair or automate mechanism to prevent
material falls.
Conduct inspection and refill or repair AC gas
system as needed.
Paint the AC and TV backboards to improve
cleanliness and aesthetics of the area.
need cleaimg of the vaporizer filter and perform
water system maintenance. Schedule routine
cleaning.
Status Remarks
Lab issue and
Responsible
Sr. No. Issue Description Opening Date
Dept.
1 Leak detected in the cutting machine.
Polishing water line is clogged and water
2
cannot be used.
3 Laboratory AC pipe leaks during rainfall.
4 Comparison chart light is not working.
Collection tank behind the laboratory
5
needs to be cleaned.
Flooring is required in the laboratory
6
sample preparation area.
7 Drier machine needs a proper stand.
File rack is required for document
8
organization.
Cutting sample rack is needed near the
9
cutting machine.
b issue and improvement
Expected Actual
Action Requirement Action Taken
closing date Closing Date
Inspect and repair the leakage in the
cutting machine.
Clean or replace the clogged water line
to restore water flow.
Seal or replace the AC pipe to prevent
water leakage during rain.
Repair or replace the faulty light for
proper visibility.
Clean and maintain the collection tank
to avoid overflow or contamination.
Install suitable flooring in the designated
area for safety and cleanliness.
Fabricate or arrange a stable stand for
the drier machine.
Install a file rack to store documents
properly.
Provide a sample rack near the cutting
machine for convenient access.
Status Remarks
