QFR No - 7000891906
Defect Details
| NC No. | 7000891906 |
| NC Date | 24/01/2023 |
| NC Submission Date | |
| Part No. | 520KN00173 |
| Part Name | RESERVOIR CAP RAW CASTING |
| Supplier Name & Code | 101032-ASM CASTINGS PRIVATE LIMITED ( |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | BLOW HOLES-Blow Hole Damages |
1. Problem Description
| Defect Description | BLOW HOLES-Blow Hole Damages |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 8000 |
| 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 |
8000
|
12000
|
0
|
8000
|
2580
|
30580
|
| Check Qty |
8000
|
12000
|
0
|
8000
|
2580
|
30580
|
| NG Qty |
0
|
72
|
0
|
21
|
14
|
107
|
| Scrap | 107 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Material Re-checked & Dot Marking done on the same for identification. |
3. Process Flow
| Process Flow Description |
|---|
| R.M. Receiving - Die Casting - Fatling - Lancering & Buffing - Drilling -Shot Blasting - Final - Inspection & PDI - Packing -Dispatch. |
4. Process Details
| Process / Operation | Die Casting |
| Outsource | No |
| Machine / Cell | Die Casting |
| Machine / Cell No. | PDC-04 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Machine P.M. Not done | P.M. Check Sheet verified & Found OK | X |
| Man | New operator | Verbal Interview taken & Found OK | X |
| Tool | Die Life Over | Die History Card found Ok | X |
| Material | Chemical Composition not ok | MTC Verified & Found OK | X |
| Method | Inspection method not adeqaute | single part inspection not done (4 to 5 parts are kept in hand by inspector & Checked together) | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Blow Holes in Casting |
| Why 2 | Material pouring Method Not ok in PDC Machine |
| Why 3 | Air & Gasses mixed material poured in Production which causes blow holes. |
| Why 4 | Material Pouring Done at the time of Degassing Also |
| Why 5 | Operator not aware about stop production during Degassing. (No Training /Q-Alert Available for the Same) |
| Root Cause (Occurance) | Training not provided to operator for Stopping production during degassing process. |
Root Cause Analysis (Outflow)
| Why 1 | Inspection Method not adequate |
| Why 2 | Single part Inspection not done by Inspector (4 to 5 Part checked at once which causes flow of NG Parts) |
| Why 3 | Inspector Not aware about singe part inspection |
| Why 4 | Check Point not added in Work Instruction for single Part Inspection |
| Why 5 | |
| Root Cause (Outflow) | Check Point not added in Work Instruction for single Part Inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Training Provided to Operators for Stopping production during degassing | Lalit Sahrma | 01/02/2023 | 01/02/2023 | Completed |
| Outflow | Check point added in Work Instruction for Single Part Inspection . | Ateev Sharma | 01/02/2023 | 01/02/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Single Part Inspection started in-place of 4 to 05 parts in final inspection. |
| 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) |
Operator was not aware about Stopping Production during Degassing. 350_Occurance_Before.pdf |
| Occurance (After) |
Training Provided to Operators for Stopping production during Degassing. 350_Occurance_After.pdf |
| Outflow (Before) |
check point was not available in W.I. for Single part Inspection 350_Outflow_Before.pdf |
| Outflow (After) |
Check Point added in W.I. for Single Part Inspection. 350_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | PDC |
12. Document Review
| Documents | PFMEA, WISOP |
| Specify Other Document | Training Record |
13. Effectiveness Of Action
| Reviewed Quantity | 24000 |
| Reason for submission | No defect found in 3 lot |