QFR No - 7000936274
Defect Details
| NC No. | 7000936274 |
| NC Date | 10/08/2023 |
| NC Submission Date | |
| Part No. | 520AE00300 |
| Part Name | CORE PLATE 3W 4S |
| Supplier Name & Code | 100959-AAR CEE ENGINEERING WORKS UNIT |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | FLATNESS NOT OK.-flatness obs 0.30 against 0.10 mm |
1. Problem Description
| Defect Description | 3W4S Core Plate Not qualify to gap gauge (Flatness found oversize up to 0.3 mm against 0.1 mm) |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 10000 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qc@aarceeengg.com |
| Plant Head/CEO Email ID | planthead.diecasting@aarceeengg.com |
| MD Email ID | vaibhav.arora@aarceeengg.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
16000
|
0
|
0
|
7000
|
0
|
23000
|
| Check Qty |
16000
|
0
|
0
|
7000
|
0
|
23000
|
| NG Qty |
1200
|
0
|
0
|
55
|
0
|
1255
|
| Scrap | 0 |
| Rework | 1255 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Material segregated at the customer end(ETL end) & our end (AAR CEE end)NG parts to be re-shot Blasting |
3. Process Flow
| Process Flow Description |
|---|
| 10.Receipt of raw material 20.Storage of raw material 30.Holding cum melting 40. PDC stage 50.Trimming process 60.Shot Blasting 70. Barrelling process 80.Sound Testing 90.stress reliving 100.Final inspection 110.Storage & Dispatch |
4. Process Details
| Process / Operation | 60.Shot blasting & 100. Final inspection |
| Outsource | No |
| Machine / Cell | Shot blasting machine |
| Machine / Cell No. | SBM-02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Improper shot size used at shot blasting | Obsed SS 0.30 mm shot | O |
| Man | skipped at final inspection | ok limit sample not displayed at final inspection table | X |
| Method | Improper stress reliving process | Checked and found fixture flatness found up to 0.35 mm | X |
| Method | Improper cycle time at shot blasting | Found ok ,6 minutes against 5~7 minutes | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 pcs/lot |
7. Root Cause Analysis (Occurance)
| Why 1 | FLATNESS NOT OK.-flatness obs 0.30 against 0.10 |
| Why 2 | shot blasting is not done as per defined frequency. |
| Why 3 | process parameter monitoring not done. |
| Why 4 | lack of awareness of operator |
| Why 5 | |
| Root Cause (Occurance) | process parameter monitoring not done. |
Root Cause Analysis (Outflow)
| Why 1 | FLATNESS NOT OK.-flatness obs 0.30 against 0.10 |
| Why 2 | NG pieces were skipped by final inspection. |
| Why 3 | limit sample not displayed in final inspection area. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | limit sample not displayed in final inspection area. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | QC inspection given to the tanning | Mukesh | 01/09/2023 | 01/09/2023 | Completed |
| Outflow | OK LIMIT SAMPLE DISPLAY AT FINAL INSPECTION AREA | MUKESH | 03/09/2023 | 01/09/2023 | Completed |
| Occurance | Fixture corrected | Ajay Malik | 20/10/2023 | 20/10/2023 | Completed |
| Occurance | Heating Fixture validation plan made and adhere for | Ajay Malik | 23/10/2023 | 23/10/2023 | Completed |
| Outflow | Standard operating procedure made and adhere for gap gauge verification & handling | Ajay Malik | 23/10/2023 | 23/10/2023 | Completed |
| Outflow | Standard operating procedure made and adhere for gap gauge verification & handling | Ajay Malik | 23/10/2023 | 23/10/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | no change |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 10 pcs 1 h |
10. Evidance of Countermeasure
| Occurance (Before) |
FORMAT AVAILABLE BUT NOT UPDATED 524_Occurance_Before.pdf |
| Occurance (After) |
GIVEN TANNING AND RECORDED STARTED 524_Occurance_After.pdf |
| Outflow (Before) |
LIMIT SAMPLE NOT DISPLAYED 524_Outflow_Before.jpg |
| Outflow (After) |
LIMIT SAMPLE DISPLAY 524_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NO |
12. Document Review
| Documents | WISOP |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 10000 |
| Reason for submission | Repeated Occurrence at ETL end -Gap Inspection activity need to strengthen |