QFR No - 7000911552
Defect Details
| NC No. | 7000911552 |
| NC Date | 26/04/2023 |
| NC Submission Date | |
| Part No. | S2AB01907B |
| Part Name | ADJUSTER POWDER COATED |
| Supplier Name & Code | 100973-TESMO MOTORCAST PRIVATE LIMITE |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | EXCESS MATERIAL-excess material at spring resting face |
1. Problem Description
| Defect Description | Major power coating defects observed with casting concern also. |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 1200 |
| 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 |
3200
|
0
|
4200
|
3000
|
6000
|
16400
|
| Check Qty |
3200
|
0
|
0
|
3000
|
6000
|
12200
|
| NG Qty |
1200
|
0
|
0
|
0
|
0
|
1200
|
| Scrap | 1200 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Check point added in final stage. |
3. Process Flow
| Process Flow Description |
|---|
| PDC-REAMER-GRINDING-SURFACE TREATMENT-INSPECTION-POWDER COATING-SAMPLE INSPECTION-PACKING DESPATCH |
4. Process Details
| Process / Operation | PDC |
| Outsource | No |
| Machine / Cell | PDC-350 Ton |
| Machine / Cell No. | PDC-5 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Ejector Pin dia oversize | pin bend dia oversize & excess Flash generated | O |
| Tool | pin jam in die | pin dia oversize due to heat generation | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | visual checking |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1 |
7. Root Cause Analysis (Occurance)
| Why 1 | PIN FLASH ON SPRING RESTING FACE |
| Why 2 | EJECTOR PIN DIE INCREASE ON INSERT |
| Why 3 | DIE RUNNING WITH UNBALANCE EJECTION |
| Why 4 | SETTING NOT DONE CORRECTLY |
| Why 5 | POOR SKILL LEVEL |
| Root Cause (Occurance) | EJECTOR SETTING SKILL LEVEL NOT GOOD |
Root Cause Analysis (Outflow)
| Why 1 | PIN FLASH ON SPRING RESTING FACE |
| Why 2 | PIN FLASH CHECKING MISSED BY INSPECTOR |
| Why 3 | IMPROPER TRAINING TO INSPECTOR |
| Why 4 | VISUAL DISPLAY NOT AVAILABLE |
| Why 5 | |
| Root Cause (Outflow) | VISUAL DISPLAY OF PIN FLASH NOT AVAILABLE |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | VISUAL DISPLAY AT INSPECTION WITH PROPER TRAINING | ANKUSH | 30/06/2023 | 30/06/2023 | Completed |
| Occurance | PIN AND INSERT DIAMETER CHECKING | SACHIN | 01/07/2023 | 01/07/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | VISUAL DISPLAY IN INSPECTION TABLE WITH SAMPLES |
| Inspection Method | Other |
| Other Inspection Method | VISUAL |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1 |
10. Evidance of Countermeasure
| Occurance (Before) |
PART WITH PIN FLASH 442_Occurance_Before.jpeg |
| Occurance (After) |
EJECTOR PIN DIA INCREASE 442_Occurance_After.jpeg |
| Outflow (Before) |
PART WITH PIN FLASH 442_Outflow_Before.jpeg |
| Outflow (After) |
SAMPLE PLACED ON FINAL STAGE 442_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NO |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | PART DISPLAY |
13. Effectiveness Of Action
| Reviewed Quantity | 10 |
| Reason for submission | Corrective action parts submission. |