QFR No - 7000824219
Defect Details
| NC No. | 7000824219 |
| NC Date | 10/03/2022 |
| NC Submission Date | |
| Part No. | 165FY00422 |
| Part Name | HUB CLUTCH 3W4S MACHINED & BROACHED |
| Supplier Name & Code | 100656-MADHURA DIE CAST PVT.LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | DIMETER UNDERSIZE-minor dia u/s plug not qualify |
1. Problem Description
| Defect Description | Minor dia u/s plug not qualify |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 12 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | madhuradiecast@gmail.com |
| Plant Head/CEO Email ID | madhuradiecast@gmail.com |
| MD Email ID | madhuradiecast@gaikegroup.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1350
|
0
|
0
|
500
|
800
|
2650
|
| Check Qty |
1350
|
0
|
0
|
500
|
800
|
2650
|
| NG Qty |
12
|
0
|
0
|
2
|
0
|
14
|
| Scrap | 14 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1.100% Stock segregate at customer end and Supplier end stock. |
3. Process Flow
| Process Flow Description |
|---|
| 1.Casting 2.fetling 3. CNC 1st Set-up 4.CNC 2nd Set-up 5.Broaching 6.Final Inspection |
4. Process Details
| Process / Operation | Broaching |
| Outsource | No |
| Machine / Cell | BROACHING |
| Machine / Cell No. | MDCPL/BROACHING/01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Component was not proper kept on broaching fixture. | Broaching fixture checked and verify found ok | O |
| Man | Unskilled operator operated machine | Skill matrix plan verify operator is skillful found | O |
| Tool | Broach tool life monitoring not effectively monitor | Tool life monitoring sheet not available. | X |
| Material | Hard point impurity material is used for broaching | Component checked found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 1 : 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | Broch wear |
| Why 2 | Broach Reshaping not done as per decided frequency |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | 1.Broch wear 2.Broach tool life not monitor |
Root Cause Analysis (Outflow)
| Why 1 | Inspection frequency is less |
| Why 2 | unskilled inspector |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspection frequency is less |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 1. Inspection frequency of minor dia by plug gauge increases | QA.Supervisor | 04/01/2022 | Completed | |
| Occurance | 1.Tool life monitoring incorporated in Broaching machine. 2.Broach tool monitoring sheet is available and verify by production supervisor | Production Supervisor | 04/01/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Minor dia checking and final inspection by plug gauge on sampling bases and started 100% by plain plug gauge |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:5 |
10. Evidance of Countermeasure
| Occurance (Before) |
Broach wear broach life not effectively monitored as per decide frequency 12_Occurance_Before.jpeg |
| Occurance (After) |
Broach life monitoring started as per decide frequency & start verifying pokayoke verification sheet on weekly basis for broach machine counter 12_Occurance_After.pdf |
| Outflow (Before) |
Inspection Frequency less 01:05 on sampling basis 12_Outflow_Before.pdf |
| Outflow (After) |
Control plan updated at final inspection stage for minor dia inspection started 100% by plain plug gauge 12_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Broach Machine |
12. Document Review
| Documents | ControlPlan, PokayokeCheckSheet, InspCheckSheet |
| Specify Other Document | Broach life sheet |
13. Effectiveness Of Action
| Reviewed Quantity | 10000 |
| Reason for submission | There is one system we have implemented to monitor broach tool life why it was bypassed pl give explanation and action on same |