QFR No - 7000890664
Defect Details
| NC No. | 7000890664 |
| NC Date | 16/01/2023 |
| NC Submission Date | |
| Part No. | S2BG02502B |
| Part Name | BRACKET UN P/C KTEP |
| Supplier Name & Code | 100973-TESMO MOTORCAST PRIVATE LIMITE |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | THREADING NOT OK-Threading and Casting Defect |
1. Problem Description
| Defect Description | Major & fitment related defects like threading NG, Blow holes, cracks etc. repetitively observed. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 1100 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | rkhare@tesmomotorcast.com |
| Plant Head/CEO Email ID | harish.bala@tesmomotorcast.com |
| MD Email ID | svkallani@tesmomotorcast.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1100
|
0
|
0
|
6000
|
13000
|
20100
|
| Check Qty |
1100
|
0
|
0
|
6000
|
13000
|
20100
|
| NG Qty |
1100
|
0
|
0
|
20
|
0
|
1120
|
| Scrap | 20 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Perpendicularity checking gauge made and start hourly checking |
3. Process Flow
| Process Flow Description |
|---|
| PDC - Deburring - Remer - surface treatment - Camper - tapping - Air Cleaning - Packing |
4. Process Details
| Process / Operation | PDC |
| Outsource | No |
| Machine / Cell | 250-2 |
| Machine / Cell No. | 2 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | core pin hardness not ok | hardness testing report check | O |
| Tool | side core not proper open | gauge | O |
| Tool | Die Core Side Pin Bend | Perpendicularity gauge | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | Every Hr |
7. Root Cause Analysis (Occurance)
| Why 1 | Tap not gone up to required depth |
| Why 2 | Tap jam while completing its cycle |
| Why 3 | Hole pin perpendicularity not ok |
| Why 4 | Die core pin bend |
| Why 5 | Pin hardness not as per requirement |
| Root Cause (Occurance) | Core pin hardness not freeze. |
Root Cause Analysis (Outflow)
| Why 1 | Tap not gone up to required depth |
| Why 2 | Tap jam while completing its cycle |
| Why 3 | Hole pin perpendicularity not ok |
| Why 4 | Die core pin perpendicularity not ok |
| Why 5 | Perpendicularity not check |
| Root Cause (Outflow) | Core pin Perpendicularity checking frequency not defined. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Hourly pin hole Perpendicularity checking | Rahul | 27/06/2023 | Pending | |
| Occurance | Pin hardness freeze | Sachin | 27/06/2023 | Pending |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Perpendicularity checking started on hourly check on PDC |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 500 |
10. Evidance of Countermeasure
| Occurance (Before) |
Threading not OK 331_Occurance_Before.jpeg |
| Occurance (After) |
Threading ok 331_Occurance_After.jpeg |
| Outflow (Before) |
THREADING NOTOK 331_Outflow_Before.jpeg |
| Outflow (After) |
THREADING OK 331_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | kwpk |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | GAUGE CHEKING |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |