QFR No - 7000852947
Defect Details
| NC No. | 7000852947 |
| NC Date | 01/08/2022 |
| NC Submission Date | |
| Part No. | 520AE04002 |
| Part Name | CORE PLATE (C20002) |
| Supplier Name & Code | 100915-CHIRAG DIE CAST PVT LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | NOT AS PER SPECIFICATION-hardness obs 37 ~46 hrb against 52~62 hr |
1. Problem Description
| Defect Description | Hardness Observed 37 ~46 HRB As against 52~62 HRB |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 1000 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualityassurance@chiragdiecast.com |
| Plant Head/CEO Email ID | operationshead@chiragdiecast.com |
| MD Email ID | chirag.gupta@chiragdiecast.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
0
|
0
|
0
|
0
|
1000
|
| Check Qty |
1000
|
0
|
0
|
0
|
0
|
1000
|
| NG Qty |
1000
|
0
|
0
|
0
|
0
|
1000
|
| Scrap | 1000 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Tested samples will be send with each lot for Cross Verification |
3. Process Flow
| Process Flow Description |
|---|
| PDC , Trimming & shaving , Shot Blasting , Visual Inspection , Stress Reliving, 100% Gauging for Flatness, Packing & Dispatch |
4. Process Details
| Process / Operation | High Pressure Die Casting |
| Outsource | No |
| Machine / Cell | HPDC |
| Machine / Cell No. | PDC |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Mg. at Lower side of Specification of ADC-12 | Mg. observed in component 0.18 | O |
| Method | Measurement Variation in Hardness Testing | Difference observed upto 6 points in HRB | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 pcs . |
7. Root Cause Analysis (Occurance)
| Why 1 | Mg. found lower side 0.12% as against 0.30 Max. specification of ADC-12 |
| Why 2 | Mg. burn during HPDC process |
| Why 3 | Symptoms / phenomenon of process |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Lower side Mg.% will affect the hardness in lower side against the specification. |
Root Cause Analysis (Outflow)
| Why 1 | Part to part & Claw to claw variation ( In our samples we have observed 48 to 58 HRB |
| Why 2 | Mix up of Runner riser in PDC Process ( 2 or 3 Times) |
| Why 3 | Mixing of Runner Riser & al. Ingot is the part of process. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Hardness Tester results variation & Mg % Variation Part to Part & Claw to claw variation. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | We will send 5 Pcs duly hardness tested with each lot for cross verification. | Chirag Die Cast | 18/08/2022 | 18/08/2022 | Completed |
| Occurance | We will maintain % age of Mg. in molten Material Minimum 0.20% by addition of Pure Mg. ( On the basis of as & when required) during PDC process. | Chirag Die Cast | 18/08/2022 | 18/08/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No Change |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 Nos. |
10. Evidance of Countermeasure
| Occurance (Before) |
We were not adding Mg. during HPDC Process 217_Occurance_Before.pdf |
| Occurance (After) |
As per Process Inspection Report PDC , we have maintain the % of Mg as Min 0.2% in Molten Material & Hardness observed ( 48 to 60 HRB ) 217_Occurance_After.pdf |
| Outflow (Before) |
No submission of hardness tested samples for cross verification 217_Outflow_Before.pdf |
| Outflow (After) |
We will send 5 Pcs. duly hardness tested with each lot for cross verification at ETL to ensure variation in Testing Machine.( 10 Points band of Hardness requesting to increase ) as same Pc covered all the tolerance band. 217_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applicable for other core plates , where ETL asked for Hardness . |
12. Document Review
| Documents | WISOP |
| Specify Other Document | PIR for Mg add & HRB |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | OK |