QFR No - 7000827149
Defect Details
| NC No. | 7000827149 |
| NC Date | 23/03/2022 |
| NC Submission Date | |
| Part No. | 533KU00102 |
| Part Name | ROD GUIDE |
| Supplier Name & Code | 204749-GKN SINTER METALS PRIVATE LIMI |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | NOT AS PER SPECIFICATION-Chamfer profile not OK |
1. Problem Description
| Defect Description | Chamfer profile not OK - Step observed at chamfer of Rod guide (533KU00102) |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 5000 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | Bhaskar.Dhalawade@gknpm.com |
| Plant Head/CEO Email ID | Purushottam.Rishi@gknpm.com |
| MD Email ID | Rajesh.Mirani@gknpm.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5000
|
25000
|
0
|
0
|
0
|
30000
|
| Check Qty |
5000
|
25000
|
0
|
0
|
0
|
30000
|
| NG Qty |
5000
|
25000
|
0
|
0
|
0
|
30000
|
| Scrap | 0 |
| Rework | 30000 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Part can not be reworked at WH or Customer end , all parts ( 30K) called back for rework at GKN end |
3. Process Flow
| Process Flow Description |
|---|
| Mixing > Forming > sintering > Barreling > Chamfering > Sizing > 100% inspection > oil dipping > Final inspection > dispatch |
4. Process Details
| Process / Operation | Sizing |
| Outsource | No |
| Machine / Cell | K40 |
| Machine / Cell No. | Szing_ K40 Cell |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Tool alignment issues | Sizing die, top punch, bottom punch, core rod clearance checked and found within 0.020mm ( OK) | X |
| Machine | Free flow of material at inclind chamfer face during sizing process | Chamfer profile check by contour graph tracing ; curvature observed on chamfer face | O |
| Method | Chamfer profile not checked in sizing | Vrified control plan for chamfer angle check ; chamfer angle is checked in chamfering process howeve | O |
| Man | Unskilled operator | Skill matrix verified ; found OK | X |
| Machine | Chamfering tool worn out | Chanfering core rod inspected and found OK | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 2 |
7. Root Cause Analysis (Occurance)
| Why 1 | Curvature shape profile of C`bore chamfer causes sharp edge at the end of chamfer |
| Why 2 | Free flow of material at incline chamfer face during sizing process |
| Why 3 | Chamfer area not supported by tool at incline portion in sizing process |
| Why 4 | Degree not provided on sizing tool while sizing |
| Why 5 | |
| Root Cause (Occurance) | Degree not provided on sizing tool while sizing |
Root Cause Analysis (Outflow)
| Why 1 | Abnormal profile of core rod could not get detected during sizing inspection |
| Why 2 | Abnormal chamfer in sizing process not detected by inspector |
| Why 3 | Chamfer not checked by inspector in sizing process |
| Why 4 | Chamfer check not mentioned in sizing QC ( Only checked in chamfering process) |
| Why 5 | |
| Root Cause (Outflow) | Chamfer check not mentioned in sizing QC ( Only checked in chamfering process) |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | . Control plan to be updated for adding chamfer inspection during sizing operation | Ajay Shinde | 08/04/2022 | Completed | |
| Occurance | 2. Core rod design to be modified : chamfer profile to given on core rod instead of using plain core rod. | Ajay Shinde | 08/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | chamfer degree inspection during sizing operation |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 2 / batch |
10. Evidance of Countermeasure
| Occurance (Before) |
|
| Occurance (After) |
|
| Outflow (Before) |
|
| Outflow (After) |
|
11. Horizontal Deployment
| Horizontal Deployment Required | |
| Applicable Machine / Model / Plant |
12. Document Review
| Documents | |
| Specify Other Document |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |