QFR No - 7000884827
Defect Details
| NC No. | 7000884827 |
| NC Date | 21/12/2022 |
| NC Submission Date | |
| Part No. | 520CE00502 |
| Part Name | CLUTCH SHAFT ASSEMBLY DI ENGINE |
| Supplier Name & Code | 200172-AURANGABAD AUTO ENGG PVT LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | M/CING SHIFT.-Key width position shift |
1. Problem Description
| Defect Description | Hole Position shift w.r.t key way slot |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 100 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | verma.aaepl@gmail.com |
| Plant Head/CEO Email ID | aaepl.pantnagar@sangkaj.com |
| MD Email ID | steel@sangkaj.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
280
|
0
|
0
|
0
|
0
|
280
|
| Check Qty |
280
|
0
|
0
|
0
|
0
|
280
|
| NG Qty |
80
|
0
|
0
|
0
|
0
|
80
|
| Scrap | 80 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% WIP rechecked by visual Inspection |
3. Process Flow
| Process Flow Description |
|---|
| Pressing - CNC - Bush pressing - OD grinding - Keyway broaching . |
4. Process Details
| Process / Operation | Keyway broaching |
| Outsource | No |
| Machine / Cell | Broaching Machine |
| Machine / Cell No. | Gear Cell |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Part not located in broaching fixture | Locating pin length short | 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 | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Locating hole Dia. 5mm position shift w.r.t. keyway Broaching. |
| Why 2 | Keyway Broaching shift during broachng operation. |
| Why 3 | Hole not guide in position in pin |
| Why 4 | Less Awareness of operator for process |
| Why 5 | |
| Root Cause (Occurance) | Less Awareness of operator for process. |
Root Cause Analysis (Outflow)
| Why 1 | Locating hole Dia. 5mm position shift w.r.t. keyway Broaching. |
| Why 2 | Hole w.r.t. Keyway broaching relation gauge done on Sampling basis. |
| Why 3 | Hole w.r.t. Keyway broaching relation gauge done on Sampling basis. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Hole w.r.t. Keyway broaching relation gauge done on Sampling basis. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1) Hole guide pin position height incressed from 2mm to 8mm. 2) Concern operator training provided for this defect. | Mr.BAde | 31/12/2022 | 29/12/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 1) Hole w.r.t. Keyway broaching relation gauge done on 100%. 2) After Gauge insection 100% visual inspection with identification line marking with marker putted on face. 3)All final inspector training provided for this defect. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Less Awareness of operator for process. 325_Occurance_Before.xlsx |
| Occurance (After) |
1) Hole guide pin position height increased from 2mm to 8mm.
2) Concern operator training provided for this defect. 325_Occurance_After.xlsx |
| Outflow (Before) |
Hole w.r.t. Keyway broaching relation gauge done on Sampling basis. 325_Outflow_Before.xlsx |
| Outflow (After) |
1) Hole w.r.t. Keyway broaching relation gauge done on 100%.
2) After Gauge insection 100% visual inspection with identification line marking with marker putted on face.
3)All final inspector training provided for this defect. 325_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | No |
12. Document Review
| Documents | ControlPlan, PokayokeCheckSheet, PFMEA, WISOP |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | OK |