QFR No - 7000949879
Defect Details
| NC No. | 7000949879 |
| NC Date | 04/10/2023 |
| 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 | NOT AS PER SPECIFICATION-Tepar M/c 6.+0.5 u/s 4.95~5.95mm |
1. Problem Description
| Defect Description | Tapper Machining -Dimn 6+0.5 mm found 4.95~5.95 mm |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 1650 |
| 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 |
500
|
0
|
0
|
500
|
500
|
1500
|
| Check Qty |
500
|
0
|
0
|
500
|
500
|
1500
|
| NG Qty |
2
|
0
|
0
|
1
|
0
|
3
|
| Scrap | 3 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1.Casting 2.fetling 3. CNC 1st Set-up 4.CNC 2nd Set-up 5.Drilling & Tapping 6.Final Inspection |
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 | CNC 2nd Set-up |
| Outsource | No |
| Machine / Cell | 02 |
| Machine / Cell No. | CNC |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Burr resting on face | Verified & Found ok | O |
| Man | Unskilled operator was operate machine | Skill Matrix verify found OK | O |
| Machine | Loader dia is less as compare to part resting area | Loader dia is found not ok | X |
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 | 1:1 |
7. Root Cause Analysis (Occurance)
| Why 1 | Tapper Machining-Dimn 6+0.5 mm found 4.95~5.95 mm |
| Why 2 | Taper machining Problem on friction face |
| Why 3 | CNC Machine Loader not covering complete resting area of part. |
| Why 4 | Loader dia is less as compare to part resting area |
| Why 5 | |
| Root Cause (Occurance) | Loader dia is less as compare to part resting area |
Root Cause Analysis (Outflow)
| Why 1 | Taper Machining not checking at Final stage. |
| Why 2 | Taper Machining checking not added in final inspection check sheet |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Taper Machining checking not added in final inspection check sheet. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 1. Started 100% Visual inspection of taper machining at Final Stage. 2. OPL displayed at Final stage. 3. Quality alert is displayed at Final Stage. | Quality Supervisor | 15/10/2023 | 11/10/2023 | Completed |
| Occurance | Before loader dia was 48.0 mm & now increased by 59.0 mm as per part resting area. | Production Supervisor | 15/10/2023 | 11/10/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Started 100% Visual inspection of taper machining at Final Stage. |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
Before loader dia was 48.0 mm 567_Occurance_Before.jfif |
| Occurance (After) |
now increased by 59.0 mm as per part resting area. 567_Occurance_After.jpg |
| Outflow (Before) |
Taper Machining checking not added in final inspection check sheet. 567_Outflow_Before.pdf |
| Outflow (After) |
1. Started 100% Visual inspection of taper machining at Final Stage. 2. OPL displayed at Final stage. 3. Quality alert is displayed at Final Stage. 567_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | CNC |
12. Document Review
| Documents | ControlPlan, PFMEA, InspCheckSheet |
| Specify Other Document | OPL,QUALITY ALERT |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | OK |