QFR No - 7000829356
Defect Details
| NC No. | 7000829356 |
| NC Date | 02/04/2022 |
| NC Submission Date | |
| Part No. | 520AE00400 |
| Part Name | CORE PLATE REDUCED 612 |
| Supplier Name & Code | 100959-AAR CEE ENGINEERING WORKS UNIT |
| ETL Plant | 1135-ETL 7/10 P Nagar |
| Defect Details | SURFACE FINISH NOT OK- |
1. Problem Description
| Defect Description | Shot Blasting not done on plates and in some plates Shot blasting done on one side. |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 5000 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qc@aarceeengg.com |
| Plant Head/CEO Email ID | planthead.diecasting@aarceeengg.com |
| MD Email ID | vaibhav.arora@aarceeengg.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5000
|
0
|
0
|
0
|
0
|
5000
|
| Check Qty |
5000
|
0
|
0
|
0
|
0
|
5000
|
| NG Qty |
5000
|
0
|
0
|
0
|
0
|
5000
|
| Scrap | 0 |
| Rework | 5000 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 5000 pcs lot return back to supplier end (AAR CEE), New Ok lot provided for the same. |
3. Process Flow
| Process Flow Description |
|---|
| 1. Receipt of Raw Material 20. Storage of Raw Material 30. Holding Cum Melting 40. PDC 50. Trimming 60. Shot Blasting 70. Barrelling 80. Sound Testing 90. Stress Relieving 100. Final Inspection & Packing 110. Storage & Dispatch |
4. Process Details
| Process / Operation | 60. Shot Blasting |
| Outsource | No |
| Machine / Cell | Shot Blasting Machine |
| Machine / Cell No. | SBM-02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 pieces |
7. Root Cause Analysis (Occurance)
| Why 1 | Shot blasting was not done due to Shot leakage from the shot blasting machine |
| Why 2 | Shot leakage due to machine body wear out from the backside of the machine |
| Why 3 | Machine body wear out due to liner bolt broken |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Liner Bolt broke at the inner side of the liner. |
Root Cause Analysis (Outflow)
| Why 1 | Shot blasting was not done on core plates due to final inspectors were not able to detect the pieces |
| Why 2 | Due to barrelling process, it is not possible to detect such kinds of pieces by final inspectors |
| Why 3 | Ra value checks at only PDIR after barrelling process. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Ra value checks at only PDIR after barrelling |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | At final inspection WI Ra value checkpoint to be added to check per hour |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5pcs/hr |
10. Evidance of Countermeasure
| Occurance (Before) |
The liner bolt broke at the inner side of the liner 38_Occurance_Before.jpeg |
| Occurance (After) |
The Liner bolt changed 38_Occurance_After.pdf |
| Outflow (Before) |
At final inspection only PDIR done 38_Outflow_Before.pdf |
| Outflow (After) |
Now at the final inspection Roughness value to be checked for every hour & if roughness found less then lot to be hold & re-shot blasting to be done 38_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All core plate models |
12. Document Review
| Documents | WISOP |
| Specify Other Document | No other documents |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |