QFR No - 7000944097
Defect Details
| NC No. | 7000944097 |
| NC Date | 12/09/2023 |
| NC Submission Date | |
| Part No. | 520PP01902 |
| Part Name | WHEEL CLUTCH FINISHED UPGRADE |
| Supplier Name & Code | 100656-MADHURA DIE CAST PVT.LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | DAMAGES-HEAVY B/H , DAMAGE HARD SPOT ,CHIP OFF |
1. Problem Description
| Defect Description | Heavy Blow Hole observed at Friction face & Lug Face |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 2640 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | madhuradiecast@gmail.com |
| Plant Head/CEO Email ID | madhuradiecast@gmail.com |
| MD Email ID | madhuradiecast@gaikegroup.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
0
|
0
|
0
|
500
|
1000
|
1500
|
| Check Qty |
0
|
0
|
0
|
500
|
1000
|
1500
|
| NG Qty |
0
|
0
|
0
|
1
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% SEGERATION DONE AT SUPPLIER END STARTED BLUE IDENTIFICATION DOT MARK ON COMPONENTS |
3. Process Flow
| Process Flow Description |
|---|
| 1.Casting 2.fetling 3. CNC 1st Set-up 4.CNC 2nd Set-up 5.Drilling & Tapping 6.Final Inspection |
4. Process Details
| Process / Operation | casting |
| Outsource | No |
| Machine / Cell | HPDC 400T |
| Machine / Cell No. | 2 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Training not given to Operator | Training Plan and on job training record checked. | O |
| Material | Degassing Frequency | Melting cum furnace degassing report verified & found ok. | O |
| Tool | Cooling system of die | Cooling system of die found ok condition | O |
| Machine | Injection pressure | Injection pressure was not constant for every shot | X |
| Man | Unskill operator on machine | Skill matrix verified & Found ok. | 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 | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Heavy Blow Hole observed at Friction Face & Lug Face |
| Why 2 | Injection pressure was not constant for every shot. |
| Why 3 | The accumulator cylinder pressure was not constant. |
| Why 4 | The foam was generated due to the oil and N2 gas mixed up. |
| Why 5 | |
| Root Cause (Occurance) | The oil seal of the accumulator piston leaked. |
Root Cause Analysis (Outflow)
| Why 1 | Heavy Blow Hole Observed at Friction Face & Lug Face |
| Why 2 | Ok parts & Not ok Parts are mixed at the final stage |
| Why 3 | The tag was not available for the ok bins and not the ok bins. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | The tag was not available for the ok bins and not the ok bins. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1 Heat exchanger temperature maintained on lower side and machine temperature maintained between 45° C to 50° C. 2.Heat exchanger tubes & descaling done. 3.Cooling tower unit clean and descaling done. | Production Supervisor | 29/09/2023 | 29/09/2023 | Completed |
| Outflow | 1.Defective photos big size of board made and displayed. 2.Defective part handling procedure made in local language and A3 SIZE holding displayed. 3. Eye sequence chart in local language and A3 SIZE holding displayed at final inspection table. 4.Training and awareness given to Inspector. 5.Inspector Licenses implemented 6.Lux level maintained as per standard | Quality Engineer | 29/09/2023 | 29/09/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % visual inspection started with identification Marking |
| 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) |
The cooling tower unit was not clean and descaling. 550_Occurance_Before.png |
| Occurance (After) |
1. Heat exchanger tube descaling done.
2. Cooling tower unit clean and descaling done. 550_Occurance_After.png |
| Outflow (Before) |
identification tag was not available in the final inspection bin. 550_Outflow_Before.jfif |
| Outflow (After) |
Awarness Training Provide to Final Inspection Inspector & Parts Loading operator. 550_Outflow_After.jfif |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | ALL ETL COMPONENT |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | QA OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Ok |