QFR No - 7000834209
Defect Details
| NC No. | 7000834209 |
| NC Date | 30/04/2022 |
| NC Submission Date | |
| Part No. | 520FN01902 |
| Part Name | CLUTCH HOLDER BM-150 |
| Supplier Name & Code | 202375-ADVANTECH ENGINEERING COMPANY |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | DIMETER UNDERSIZE-4Hole Dia 6.2+01 o/s no go Gauge Qualyfn |
1. Problem Description
| Defect Description | 4 Hole Dia 6.2+01 oversize no go Gauge Qualifying |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 320 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@advantechgroup.co.in |
| Plant Head/CEO Email ID | info@advantechgroup.co.in |
| MD Email ID | harishpathade@advantechgroup.co.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1200
|
0
|
0
|
1500
|
800
|
3500
|
| Check Qty |
1200
|
0
|
0
|
1500
|
800
|
3500
|
| NG Qty |
320
|
0
|
0
|
0
|
0
|
320
|
| Scrap | 320 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| On VMC PCD Hole Carbide step drill (size 6.28 mm) replaced and new size of drill 6.24 mm for maintain hole ID 6.2+0.1 mm. Drill change frequency after 40000 nos. |
3. Process Flow
| Process Flow Description |
|---|
| Receiving of Casting + CNC Turning -- VMC 4 hole drilling --- Final inspection --Dispatch |
4. Process Details
| Process / Operation | CNC- Turning, VMC- PCD hole Drill |
| Outsource | No |
| Machine / Cell | Machine Shop |
| Machine / Cell No. | VMC - 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | PCD hole ID 6.2+0.1 mm taken higher side. | No Go pass | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 32 |
7. Root Cause Analysis (Occurance)
| Why 1 | PCD Hole ID 6.2+0.1 mm No GO Passed |
| Why 2 | PCD hole ID 6.2 +0.1 taken higher side as per customer requirement. |
| Why 3 | PCD hole step drill size 6.28 mm |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | On VMC PCD hole step drill size 6.28 mm |
Root Cause Analysis (Outflow)
| Why 1 | PCD Hole ID 6.2+0.1 mm No GO Passed |
| Why 2 | PCD hole ID - inspection not done with plug gauge at final stage. |
| Why 3 | PCD hole ID by Plug gauge - I Do I check by operator at Machining stage. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | PCD hole ID by Plug gauge - I Do I check by operator at Machining stage. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1. On VMC PCD hole step drill size 6.28 mm replaced with new size 6.24 mm 2. Hole ID inspection started by Plug gauge at final stage on sampling basis. | Mr. Kuldeep /Vasant | 03/05/2022 | 03/05/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Hole ID inspection started by Plug gauge at final stage on sampling basis. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10 |
10. Evidance of Countermeasure
| Occurance (Before) |
PCD Hole Step Drill Size-6.28 mm 83_Occurance_Before.xlsx |
| Occurance (After) |
PCD Hole Step Drill Size-6.24 mm 83_Occurance_After.xlsx |
| Outflow (Before) |
Plug Gauge inspection at VMC machine after hole drill operation 83_Outflow_Before.xlsx |
| Outflow (After) |
Plug gauge inspection started at final stage as per sampling plan 83_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, WISOP, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 10000 |
| Reason for submission | Cause side and inspection side action not proper |