QFR No - 7000943532
Defect Details
| NC No. | 7000943532 |
| NC Date | 11/09/2023 |
| NC Submission Date | |
| Part No. | C30400101B |
| Part Name | GEAR PRIMARY ASSLY |
| Supplier Name & Code | 100237-SANJEEV AUTO PARTS MRFS PVT LT |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | HIGHT U/SIZE.-rusty issue & boss hight obs 24.03 mm |
1. Problem Description
| Defect Description | Boss Height found undersize up to 24.03~24.07 mm against 24.10~24.20 mm |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 7 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | vpwankhade@sanjeevgroup.com |
| Plant Head/CEO Email ID | rmtiwari@sanjeevgroup.com |
| MD Email ID | maithilee@sanjeevgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1280
|
0
|
0
|
300
|
270
|
1850
|
| Check Qty |
1280
|
0
|
0
|
300
|
270
|
1850
|
| NG Qty |
513
|
0
|
0
|
11
|
6
|
530
|
| Scrap | 0 |
| Rework | 17 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Cleaning done & 100% inspection done for suspected defective batch |
3. Process Flow
| Process Flow Description |
|---|
| Sn Process Flow 1 Raw Material Inward 2 Bar Cutting 3 Billet Heating 4 Hot Forging 5 Normalizing 6 Shotblasting 7 Coining 8 Preturning 9 Peircing-1 10 Peircing-2 11 Shaving-1 12 Shaving-2 13 Milling-1 14 Milling-2 15 Finish turning 1st setup 16 Finish turning 2nd setup 17 Finish turning 3rd setup 18 Deburring 19 Final Inspection CNC Blank 20 Inward Inspection CNC Blank 21 Traciability Marking 22 Hobbing 23 Teeth Chamfering 24 Gear Shaving 25 Heat tratment 26 Shotblasting 27 ID Turning 28 Bush Pressing 29 Bush Turning 30 Washing 31 Final inspection 32 Dispatch |
4. Process Details
| Process / Operation | Shot blasting |
| Outsource | No |
| Machine / Cell | Heat treatment |
| Machine / Cell No. | HT/Shot blasting |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Dust & Moisture in shots | Dust & Moisture in shots | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 20 / lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Rusty issue / rusty spots observed on parts |
| Why 2 | Parts observed uncleaned after shot blasting |
| Why 3 | Excess dust and moisture in shots |
| Why 4 | Shots screening freqency not followed |
| Why 5 | |
| Root Cause (Occurance) | Shots screening freqency not followed |
Root Cause Analysis (Outflow)
| Why 1 | Rusty issue / rusty spots observed on parts |
| Why 2 | Parts observed uncleaned after shot blasting |
| Why 3 | Skipped from inspection |
| Why 4 | Sample inspection |
| Why 5 | |
| Root Cause (Outflow) | Sample inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Shots cleaning / screening done | Mr. Shelke | 15/09/2023 | Completed | |
| Outflow | 100% visual inspection | vpw | 12/09/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % visual inspection & sample millipore inspection |
| Inspection Method | Other |
| Other Inspection Method | Visual & millipore i |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Moisture & dust in shots 547_Occurance_Before.pdf |
| Occurance (After) |
Moisture & dust removed by shot screening & dosing lime powder 547_Occurance_After.pdf |
| Outflow (Before) |
No check point for rust 547_Outflow_Before.pdf |
| Outflow (After) |
Check point added to check rusty part 547_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | GPH all models |
12. Document Review
| Documents | WISOP, InspCheckSheet |
| Specify Other Document | WI eye sequence char |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | OK |