QFR No - 7000966074
Defect Details
| NC No. | 7000966074 |
| NC Date | 08/12/2023 |
| NC Submission Date | |
| Part No. | 520FW04702 |
| Part Name | CLUTCH HOUSING FULL FINISHED-K70 |
| Supplier Name & Code | 100656-MADHURA DIE CAST PVT.LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | OXDISED-Oxidised issue |
1. Problem Description
| Defect Description | Heavy Oxidation Issue |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 504 |
| 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 |
1000
|
1000
|
0
|
500
|
300
|
2800
|
| Check Qty |
1000
|
1000
|
0
|
500
|
300
|
2800
|
| NG Qty |
12
|
0
|
0
|
0
|
0
|
12
|
| Scrap | 12 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| .100% Stock segregate at customer end and Supplier end stock. |
3. Process Flow
| Process Flow Description |
|---|
| 1.Casting 2. fetling 3. CNC 1st Set-up 4.CNC 2nd Set-up 5.Final Inspection |
4. Process Details
| Process / Operation | Casting |
| Outsource | No |
| Machine / Cell | HPDC |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskill Operator On machine. | Skill Matrix Varified & Found OK. | O |
| Machine | water was leakage in die | Checking water leakage & Found ok | O |
| Tool | air spray gun is not in working condition | checking air spray gun found in working condition | O |
| Method | MIDC regular water supply was not available | MIDC regular water supply was not available | 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 | Oxidised Issue |
| Why 2 | Because water PH value is high. |
| Why 3 | We used Tanker water |
| Why 4 | Because MIDC regular water supply was not available . |
| Why 5 | |
| Root Cause (Occurance) | Because MIDC regular water supply was not available . |
Root Cause Analysis (Outflow)
| Why 1 | Oxidised Issue |
| Why 2 | 100% inspection not done |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | checking was sampling basis |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1.Regular MIDC water supply is started. 2. If MIDC Water is not available we will discuss with Management. | PRODUCTION SUPERVISOR | 21/12/2023 | 20/12/2023 | Completed |
| Outflow | 1. 100% die coated part separated & its inspection started. 2.Visual checking Eye Sequence Chart Displayed on Board. | QUALITY SUPERVISOR | 21/12/2023 | 20/12/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 1. 100% die coated part separated & its inspection started. 2.Visual checking Eye Sequence Chart Displayed on Board. |
| Inspection Method | Other |
| Other Inspection Method | Visual checking |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
1.MIDC regular water supply was not available . 610_Occurance_Before.jpg |
| Occurance (After) |
1.Regular MIDC water supply is started.
2. If MIDC Water is not available we will discuss with Management. 610_Occurance_After.jpg |
| Outflow (Before) |
100% inspection not done 610_Outflow_Before.jpg |
| Outflow (After) |
1. 100% die coated part separated & its inspection started.
2.Visual checking Eye Sequence Chart Displayed on Board. 610_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | EYE SEQUENCE CHART |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Alternative of MIDC Water not available -Again possibility of defect generation if MIDC water not available |