QFR No - 7000833423
Defect Details
| NC No. | 7000833423 |
| NC Date | 27/04/2022 |
| NC Submission Date | |
| Part No. | 165PP01317 |
| Part Name | WHEEL CLUTCH -4 PLATE VAVE |
| Supplier Name & Code | 101100-CAST 4 ALUMINIUM PVT LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | PCD SHIFT-4Hole Lug Pcd Not ok |
1. Problem Description
| Defect Description | 4 Hole Lug PCD Not ok |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 148 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | info@cast4aluminium.com |
| Plant Head/CEO Email ID | info@cast4aluminium.com |
| MD Email ID | kiran@cast4aluminium.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1560
|
0
|
0
|
2500
|
3000
|
7060
|
| Check Qty |
1560
|
0
|
0
|
2500
|
3000
|
7060
|
| NG Qty |
148
|
0
|
0
|
0
|
0
|
148
|
| Scrap | 148 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Recheck all pipeline material to PCD gauge. |
3. Process Flow
| Process Flow Description |
|---|
| Melting- casting- fettling- Inprocess inspection- CNC machining- 4 hole drilling and tapping- Final inspection- Packaging- Dispatch. |
4. Process Details
| Process / Operation | 4 Hole drilling & tapping. |
| Outsource | Yes |
| Machine / Cell | VMC Machine |
| Machine / Cell No. | VMC Machine |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | 1) 4 Lug Not qualify to PCD Gauge. 2) .Due to Fixture Clamping Loose One side. | Due to Fixture Clamping Loose One side. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | 4 Lug not qualify to PCD Gauge. |
| Why 2 | Fixture Clamping Loose from one side. |
| Why 3 | Due to this part not rest properly in fixture. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Fixture Clamping Loose from one side. |
Root Cause Analysis (Outflow)
| Why 1 | 100 % inspection at final stage without marking. |
| Why 2 | Operator knowledge not found evident. |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | 100 % Inspection at Final stage without marking |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Proper Tight Clamping Fixture Both side. | Mr. Thakur. | 23/03/2022 | 23/03/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Start 100% inspection with identification marking. |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Fixture PM check sheet. 73_Occurance_Before.xlsx |
| Occurance (After) |
Fixture PM check sheet & JH check sheet 73_Occurance_After.xlsx |
| Outflow (Before) |
Without marking. 73_Outflow_Before.jpg |
| Outflow (After) |
Inspection marking. 73_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Not applicable |
12. Document Review
| Documents | PMCheckSheet, JHCheckSheet, InspCheckSheet |
| Specify Other Document | Fixture check sheet. |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | OK |