QFR No - 7000940002
Defect Details
| NC No. | 7000940002 |
| NC Date | 25/08/2023 |
| NC Submission Date | |
| Part No. | S2BG04102B |
| Part Name | BRACKET UNCOATED |
| Supplier Name & Code | 100959-AAR CEE ENGINEERING WORKS UNIT |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | POROSITY-Failed in Load Testing |
1. Problem Description
| Defect Description | Bracket Failed in Breaking Load Test |
| Detection Stage | Receipt |
| Problem Severity | Safety |
| NG Quantity | 1200 |
| 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 |
2800
|
19000
|
0
|
0
|
0
|
21800
|
| Check Qty |
2800
|
10000
|
0
|
0
|
0
|
12800
|
| NG Qty |
2
|
0
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material send back to Aar cee for 100 % inspection with identification |
3. Process Flow
| Process Flow Description |
|---|
| RM Store + Melting cum holding+ HPDC+ Fettling + Reaming + Drilling + Tapping + Final Inspection+ Packing & Dispatch |
4. Process Details
| Process / Operation | HPDC & Final Inspection |
| Outsource | No |
| Machine / Cell | Mc -07 |
| Machine / Cell No. | mc-07 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | improper check load | checked and found pin using of 21 mm in the 22 inner dia during load testing in BKT 4102 | X |
| Material | Improper material used | Material found ok | O |
| Man | unskilled inspector deputed at final inspection | Found ok ,Kaushal inspector was aware about all defects | O |
| Method | Improper degassing | manual degassing done ,but not enough chance of porosity in bracket | X |
| Method | Error in UTM | Found ok ,calibration done on 1.6.23 and due on 1.6.24 | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Load testing on UTM |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 5 nos /lot |
7. Root Cause Analysis (Occurance)
| Why 1 | 4102 Bracket failed in load testing |
| Why 2 | 20 mm pin used in the 22 inner dia of 4102 bracket during load testing |
| Why 3 | model wise Pin not defined for load testing in bracket |
| Why 4 | Possibility Pin dim. of UTM fixture not considered during development |
| Why 5 | |
| Root Cause (Occurance) | Possibility Pin dim. of UTM fixture not considered during development |
Root Cause Analysis (Outflow)
| Why 1 | 4102 Bracket failed in load testing |
| Why 2 | Single pin used for load testing in bracket |
| Why 3 | Pin not defined for model wise (Inner dia) |
| Why 4 | Check point not covered in work instruction of UTM |
| Why 5 | |
| Root Cause (Outflow) | Check Point not covered in work instruction of UTM |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Density index ,vaccumization unit & auto plunger lubrication machines introduced | Bhim Singh | 03/09/2023 | 03/09/2023 | Completed |
| Occurance | Fixture pin to be made model wise for bracket load testing | Bhim Singh | 04/09/2023 | 04/09/2023 | Completed |
| Occurance | N2 degasser introduced and adhered to avoid porosity issue | Bhim Singh | 03/09/2023 | 03/09/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Pin changed and check point added in load testing work instruction Inspection started with identification |
| Inspection Method | Other |
| Other Inspection Method | UTM + Fixture |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 nos/lot |
10. Evidance of Countermeasure
| Occurance (Before) |
N/A 534_Occurance_Before.png |
| Occurance (After) |
N2 degasser, density index ,vacumization unit and auto plunger lubrication added and started 534_Occurance_After.png |
| Outflow (Before) |
N/A 534_Outflow_Before.png |
| Outflow (After) |
OPL made and adhered for load testing
Pin made and adhered for model wise bracket for load testing 534_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All bracket model |
12. Document Review
| Documents | WISOP |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 0 |
| Reason for submission | Please review the possible causes and provided proper action with actual quantity |