QFR No - 7000891160
Defect Details
| NC No. | 7000891160 |
| NC Date | 19/01/2023 |
| NC Submission Date | |
| Part No. | S2BG03908B |
| Part Name | BKT POWDER COATED |
| Supplier Name & Code | 101032-ASM CASTINGS PRIVATE LIMITED ( |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | THREADING NOT OK-Threading Not ok |
1. Problem Description
| Defect Description | Ejection pin mark observed on spring resting face. Same causing assembly function not OK. |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 520 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@asmcastings.in |
| Plant Head/CEO Email ID | skaul@asmcastings.in |
| MD Email ID | rajiv@asmcastings.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
14000
|
2500
|
0
|
3500
|
460
|
20460
|
| Check Qty |
14000
|
2500
|
0
|
3500
|
460
|
20460
|
| NG Qty |
520
|
0
|
0
|
39
|
0
|
559
|
| Scrap | 559 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation & Yellow Marking on Ok Parts |
3. Process Flow
| Process Flow Description |
|---|
| RM Receiving - Die Casting - Fattling - Reamer- Shot Blasting - Drilling & Threading - Final Inspection & PDI - Dispatch |
4. Process Details
| Process / Operation | Machining |
| Outsource | No |
| Machine / Cell | Machine Shop |
| Machine / Cell No. | SPM-02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Tool Blunt (Life Over) | Tool History Card verified & Found Ok | X |
| Machine | Tool Position not ok in machine | Machine P.M. Record verified & Found Ok | X |
| Material | R.M. of Insert not ok | MTC report verified & Found Ok | X |
| Method | Cleaning of thread not adequate in Machining | Air Application check point not available in control plan | O |
| Man | Semi Skilled operator | Skill Matrix verified & Found ok | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 Nos./hr |
7. Root Cause Analysis (Occurance)
| Why 1 | Thread not cleaned during machining |
| Why 2 | Thread Clean by Coolent only which is not adequate . |
| Why 3 | No Check point added in control plan for Air Cleaning of thread in machining. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | No Check Point added in Control Plan for Air Cleaning of Thread in Machining. |
Root Cause Analysis (Outflow)
| Why 1 | Thread NG Parts skipped from Final Inspection |
| Why 2 | Inspector Not aware |
| Why 3 | Limit Sample not displayed at Final Inspection area. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Limit Sample Not Displayed at final Inspection area. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Check Point added in Control Plan for Air Cleaning in machining. | Lalit Sharma | 01/02/2023 | 01/02/2023 | Completed |
| Outflow | Limit Sample displayed at Final Inspection area | Ateev Sharma | 01/02/2023 | 01/02/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | Inspection System is same although Limit sample is displayed . |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Check point not available in control plan for air cleaning 334_Occurance_Before.pdf |
| Occurance (After) |
Check Point added in control plan for Air Cleaning 334_Occurance_After.pdf |
| Outflow (Before) |
Limit sample not available at final inspection area 334_Outflow_Before.jpeg |
| Outflow (After) |
limit sample provided at final inspection area. 334_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | SPM Machine |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | Q-Alert |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | Completed. |