QFR No - 7000939009
Defect Details
| NC No. | 7000939009 |
| NC Date | 23/08/2023 |
| NC Submission Date | |
| Part No. | 520FN02602 |
| Part Name | CLUTCH HOLDER (C20002) |
| Supplier Name & Code | 101067-MEGA METALS |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | EXTRA METAL-Extra metrial 1cavity & Heat check |
1. Problem Description
| Defect Description | Extra Material at Bolt resting face-Fitment issue |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 1200 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | mukesh.pathak@megametalsindia.com |
| Plant Head/CEO Email ID | lalit.goel@megametalsindia.com |
| MD Email ID | raman.arora@megametalsindia.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
2000
|
0
|
500
|
2000
|
5500
|
| Check Qty |
1000
|
2000
|
0
|
500
|
2000
|
5500
|
| NG Qty |
250
|
500
|
0
|
5
|
0
|
755
|
| Scrap | 5 |
| Rework | 750 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Defected lot quarantine, segregated and reworked ETL Stock as well as Mega Metals stock |
3. Process Flow
| Process Flow Description |
|---|
| PDC , Fettling, Machining, Final Inspection, PDIR, Dispatch |
4. Process Details
| Process / Operation | PDC |
| Outsource | No |
| Machine / Cell | PDC |
| Machine / Cell No. | HPDC-04 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Slipped from inspection | WI Checked and Verified with Inspectors | O |
| Tool | Heat Crack in die at C1Cavity at specific area | Verification done insert found the minor heat crack in die | O |
| Method | Could not removed in fettling | It was not pre decided /was not in WI | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | No |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Extra metal on clutch holder |
| Why 2 | Due to dent in die. |
| Why 3 | Dent occurred during the removing stucked flash |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Dent occurred during the removing stucked flash. |
Root Cause Analysis (Outflow)
| Why 1 | Extra metal on clutch holder |
| Why 2 | Part slipped from final inspection |
| Why 3 | Because check point not available in WI. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Because check point not available in WI. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | laser welding done | suresh | 15/12/2023 | 01/09/2023 | Completed |
| Outflow | WI revise | Rajesh | 16/12/2023 | 30/08/2023 | Completed |
| Outflow | training provided to all inspectors | Rajesh | 15/12/2023 | 04/09/2023 | Completed |
| Occurance | training provided to all operators | Arun kumar | 15/12/2023 | 04/09/2023 | Completed |
| Outflow | Quality alert displayed on final inspection table | Subhash kumar | 30/08/2023 | 30/08/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | check point added |
| Inspection Method | Other |
| Other Inspection Method | visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Quality Alert -Before condition picture 530_Occurance_Before.pdf |
| Occurance (After) |
OJT 530_Occurance_After.pdf |
| Outflow (Before) |
Before After of WI
Before WI 530_Outflow_Before.pdf |
| Outflow (After) |
Revised WI 530_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Only one Part running at our end |
12. Document Review
| Documents | PFMEA, WISOP |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |