QFR No - 7000920866
Defect Details
| NC No. | 7000920866 |
| NC Date | 09/06/2023 |
| NC Submission Date | |
| Part No. | 538FL00102 |
| Part Name | PISTON NUT - WP |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | EXCESS MATERIAL-DO BURR |
1. Problem Description
| Defect Description | Burr found on hex |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 1889 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | 2qwja5mj5mgg3izzjrxtdfil.jpg |
Supplier Communication Details
| Quality Head Email ID | quality@mahavirind.co.in |
| Plant Head/CEO Email ID | planthead@mahavirind.co.in |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2400
|
0
|
0
|
600
|
0
|
3000
|
| Check Qty |
2400
|
0
|
0
|
600
|
0
|
3000
|
| NG Qty |
1889
|
0
|
0
|
0
|
0
|
1889
|
| Scrap | 0 |
| Rework | 1889 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Suspected Material Segregation at Customer End |
3. Process Flow
| Process Flow Description |
|---|
| Forging Finish Inward -Raw Material Store- CNC-1- CNC-2- Plating- Final Inspection - Packing - Dispatch - |
4. Process Details
| Process / Operation | CNC-1&2 |
| Outsource | No |
| Machine / Cell | CNC-13 |
| Machine / Cell No. | CNC section |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Insert Corner Wear | Insert Run Than decide tool life | 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 | 1005 |
7. Root Cause Analysis (Occurance)
| Why 1 | Burr found on hex |
| Why 2 | Excess Burr Sticking at Across Corner Area |
| Why 3 | During CNC process Across Corner Area Excess Material Not removed. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | During CNC process Across Corner Area Excess Material Not removed. |
Root Cause Analysis (Outflow)
| Why 1 | Burr found on hex |
| Why 2 | During Sampling Burr effected Material Not Detected |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | During Sampling Burr effected Material Not Detected |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Deburring Process Add After Both CNC Operation | Plant Head | 01/07/2023 | 03/07/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Visual Inspection Instead Of Sampling 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) |
Before - After CNC Process Deburring not Done to Every Part Only Heavy excess Burr Part Deburring. 470_Occurance_Before.docx |
| Occurance (After) |
100% Deburring Process Start Each Part after CNC Process 470_Occurance_After.docx |
| Outflow (Before) |
Sampling Visual Inspection 470_Outflow_Before.docx |
| Outflow (After) |
100% Visual Inspection Start Before Dispatch . 470_Outflow_After.docx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Spacer Tubes |
12. Document Review
| Documents | ControlPlan, PFMEA, ProcessFlowChart |
| Specify Other Document | Nil |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | no any issue observed after action submitted. |