QFR No - 7000965699
Defect Details
| NC No. | 7000965699 |
| NC Date | 08/12/2023 |
| NC Submission Date | |
| Part No. | 520FG08402 |
| Part Name | GEAR PRIMARY DRIVEN (discover 125 cc) |
| Supplier Name & Code | 100987-FLASH VIVEN MACHINING TECHNOLO |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | DIAMETER OVER SIZE-dia 36.0+0.016 found 36.036 mic |
1. Problem Description
| Defect Description | ID Found oversize up to 36.036 mm against 36 +0.016 mm |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 17 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | srk.quality@flashgroup.in |
| Plant Head/CEO Email ID | dkj.mfg@flashgroup.in |
| MD Email ID | sv.md@flashgroup.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
1500
|
0
|
2500
|
1590
|
7590
|
| Check Qty |
2000
|
1500
|
0
|
2500
|
1590
|
7590
|
| NG Qty |
17
|
0
|
0
|
0
|
0
|
17
|
| Scrap | 17 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All WIP segregated |
3. Process Flow
| Process Flow Description |
|---|
| Forging - CNC Turning - Hobbing - Heat Treatment - Shot Blasting - ID Honing - Teeth Honing - Final Inspection - Packing & dispatch |
4. Process Details
| Process / Operation | ID Honing |
| Outsource | No |
| Machine / Cell | Nagel-2 |
| Machine / Cell No. | Hard Cell |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Excess material removed during ID honing | Spindle relay malfunctioning | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10 |
7. Root Cause Analysis (Occurance)
| Why 1 | Excess material remove from id |
| Why 2 | Ladges not retract to original position after expansion |
| Why 3 | spindle not retract to upward, and continuously rotating inside components |
| Why 4 | spindle relay malfunction |
| Why 5 | |
| Root Cause (Occurance) | spindle relay malfunction |
Root Cause Analysis (Outflow)
| Why 1 | Not detected during final inspection |
| Why 2 | Only sampling inspection |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Only sampling inspection at final inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | spindle relay replaced | adk | 14/12/2023 | 14/12/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | no change |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Machine spindle relay malfunctioning 609_Occurance_Before.pdf |
| Occurance (After) |
Machine spindle relay replaced 609_Occurance_After.pdf |
| Outflow (Before) |
Sampling inspection at Final inspection 609_Outflow_Before.pdf |
| Outflow (After) |
100% inspection started at Final inspection 609_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Nagel 1 |
12. Document Review
| Documents | PMCheckSheet, InspCheckSheet |
| Specify Other Document | N/A |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Ok |