QFR No - 7000884966
Defect Details
| NC No. | 7000884966 |
| NC Date | 21/12/2022 |
| NC Submission Date | |
| Part No. | 520AE05702 |
| Part Name | CORE PLATE - SHINE & UNICORN |
| Supplier Name & Code | 101145-STAR PROJECTS INDIA |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | FLATNESS NOT OK.-Not qualify to gap gaue |
1. Problem Description
| Defect Description | Not qualify to gap gauge (Flatness found up to 0.2 mm against 0.1 mm) |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 1615 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualityhead@starprojectsindia.com |
| Plant Head/CEO Email ID | engineering@starprojectsindia.com |
| MD Email ID | ishant@starprojectsindia.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
8000
|
23000
|
46000
|
0
|
10000
|
87000
|
| Check Qty |
8000
|
5000
|
0
|
0
|
4500
|
17500
|
| NG Qty |
1615
|
211
|
0
|
0
|
8
|
1834
|
| Scrap | 1615 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Material has been hold for 100 % Re-inspection with proper identification |
3. Process Flow
| Process Flow Description |
|---|
| Receipt of Raw material+ Storage of raw material+ Hold cum melting +PDC+ First Trimming +Shot Blast+2nd Trimming+ Barreling +Shot blasting+ sound testing+ stress relieving +final inspection & packing +Storage & dispatched |
4. Process Details
| Process / Operation | PDC & Final Inspection |
| Outsource | No |
| Machine / Cell | MC-10 |
| Machine / Cell No. | MC-10 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Negligency Done by Inspector | Baijnath,Rekha,Shyamveer)Training record & Skill amtrix available for same(F13/P&A(OJT),found ok | O |
| Machine | Gap Gauge Wear Out | Gap Gauge Validation & Verification Plan Available and Adhered (F07/QAD(JFR) | O |
| Method | Improper flatness of stress relieving fixture | Fixture validation plan available and adhered(F07A/QAD(JFR) | O |
| Method | Tie bar Bolt Balancing | Tie Baar Bolt Was found Un-Balance | X |
| Method | Improper Stress relieving Parameter | Stress relieving Parameter Observed Temp. 261°C against 270±20°C ,Time obsd 30 minutes Against 25±5 | 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 | Per Lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Core Plate-C101 Not Qualify to gap gauge |
| Why 2 | One face of the die was found in tapper |
| Why 3 | Tie bar Bolt was found Un-Balance |
| Why 4 | Tie bar Bolt Locking or fix mechanism not available |
| Why 5 | Possibility not considered during define the daily machine check sheet |
| Root Cause (Occurance) | Tie bar Bolt Locking Mechanism Broken |
Root Cause Analysis (Outflow)
| Why 1 | Core Plate-C101 Not Qualify to gap gauge |
| Why 2 | 100% parts was not passed from gap gauge. |
| Why 3 | Gap gauge set on 2.12 mm but as per existing part calculation should be 2.09 mm |
| Why 4 | Gap gauge size can be change as per part thickness |
| Why 5 | Gap gauge setting frequency not defined |
| Root Cause (Outflow) | Due to Base Size and lug size of Receiving gauge was set at higher Point. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Tool history to be maintained | Ajay Malik | 26/12/2022 | 26/12/2022 | Completed |
| Outflow | 200% inspection started with identification ,Identification also defined for warehouse and star end. | Ajay Malik | 22/12/2022 | 22/12/2022 | Completed |
| Outflow | Gap gauge setting & verification started on daily basis as per (15 part avg. thickness +Flatness +Passing allowance 10 microns) | Ajay Malik | 23/12/2022 | 23/12/2022 | Completed |
| Outflow | Gap gauge size varification check point added in Pre-Dispatch inspection report | Ajay Malik | 23/12/2022 | 23/12/2022 | Completed |
| Occurance | Daily Machine check sheet updated | Ajay Malik | 26/12/2022 | 26/12/2022 | Completed |
| Outflow | Quality Alert made and displayed at concerned area | Ajay Malik | 22/12/2022 | 22/12/2022 | Completed |
| Outflow | Training has been provided to Operator | Ajay Malik | 22/12/2022 | 22/12/2022 | Completed |
| Occurance | Tie Bar Bolt Locking Mechanism to be made and freezed | Ajay Malik | 30/12/2022 | 30/12/2022 | Completed |
| Occurance | Tie Bar Bolt Locking Mechanism to be made and freezed | Ajay Malik | 22/12/2022 | 22/12/2022 | Completed |
| Occurance | .PDC Tool to be rectified and thickness maintain on 1.95 to 2.00 mm instead of 1.95 ~2.05 mm | Ajay Malik | 26/12/2022 | 26/12/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Gap gauge setting & verification started on daily basis as per (15 part avg. thickness +Flatness +Passing allowance 10 microns |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | Per Lot |
10. Evidance of Countermeasure
| Occurance (Before) |
Tie bar Bolt Locking or fix mechanism not available 324_Occurance_Before.pdf |
| Occurance (After) |
Tie Bar Bolt Locking Mechanism to be made and freezed 324_Occurance_After.pdf |
| Outflow (Before) |
Gap gauge set on 2.12 mm but as per existing part calculation should be 2.09 mm 324_Outflow_Before.pdf |
| Outflow (After) |
Gap gauge setting & verification started on daily basis as per (15 part avg. thickness +Flatness + Passing allowance 10 microns) 324_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Models of Core Plate |
12. Document Review
| Documents | WISOP, InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | OK |