QFR No - 7000987844
Defect Details
| NC No. | 7000987844 |
| NC Date | 20/02/2024 |
| NC Submission Date | |
| Part No. | 520JT05102 |
| Part Name | PLATE CLUTCH PIAGGIO |
| Supplier Name & Code | 101138-HINDUSTAN PRESSINGS PVT.LTD. |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | CRACK-Crack issue |
1. Problem Description
| Defect Description | Plate Clutch observed Crack |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 3900 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | odwx25kgwj1e0posgteq0nl2.jpg |
Supplier Communication Details
| Quality Head Email ID | quality.p1@hpplindia.com |
| Plant Head/CEO Email ID | spatil@hpplindia.com |
| MD Email ID | rakesh@hpplindia.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
3900
|
0
|
0
|
0
|
0
|
3900
|
| Check Qty |
3900
|
0
|
0
|
0
|
0
|
3900
|
| NG Qty |
88
|
0
|
0
|
0
|
0
|
88
|
| Scrap | 88 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| We have imidiate action check for crack and NG parts segragation done. |
3. Process Flow
| Process Flow Description |
|---|
| RM - Blanking/Piercing - Sandering - Nitriding - Dishing - Final Inspection - Packing |
4. Process Details
| Process / Operation | Dishing |
| Outsource | No |
| Machine / Cell | PP 17 |
| Machine / Cell No. | 110T |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | FINAL INSPECTION NOT CHECKE DPROPPELY | INSPECTOR CHECKED IN GAUGE AFTER REWOK JOB | X |
| Method | REWOK JOB NOT PROPERLY DONE | EXCESS PRESSURE GIVEN ON PART OBSERVED IN VISUAL DEFECT | 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 | LOT SIZE |
7. Root Cause Analysis (Occurance)
| Why 1 | Crack found |
| Why 2 | Parts gets excess pressure during staraightning process |
| Why 3 | Rework parts (Go gauge not Ok) passing through process |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Rewok Parts (Go Gauge not Ok) passing througth Straigjtning proces |
Root Cause Analysis (Outflow)
| Why 1 | Crack found |
| Why 2 | 100% inspection done ok parts.In rework parts check visual inspection |
| Why 3 | Inspector aware about the checking hair line crack in rework parts. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspector aware about the checking hair line crack in rework parts. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | WI for the rework parts (Go gauge not Ok) passed throught straightning and check parts visualyy by 100% and parts indetified seperatly | Mr. Hitendra Patil(HPPL) and Mr, Kiran(HPPL) | 07/03/2024 | 09/03/2024 | Completed |
| Occurance | Traininh give to supervisor and opearartor to rework procedure. | Mr. Hitendra Patil(HPPL) and Mr, Kiran(HPPL) | 07/03/2024 | 09/03/2024 | Completed |
| Outflow | 1. Inspector training regarding all final inspection of rework job by 100% 2. 100% checked the gauge passing throught plates and varify the experienced senior QA person for next 3 lot | Mr.Kiran ( HPPL | 12/03/2024 | 13/03/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | REWORK PARTS VISUAL INSPECTION DONE AS PER WORK INSTRUCTION. |
| Inspection Method | Other |
| Other Inspection Method | VISUAL |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | LOT SIZE |
10. Evidance of Countermeasure
| Occurance (Before) |
Work instruction not avilable 687_Occurance_Before.pdf |
| Occurance (After) |
We have training given to opearator as per work instruction 687_Occurance_After.pdf |
| Outflow (Before) |
Check job visually not q alerat avilable 687_Outflow_Before.pdf |
| Outflow (After) |
Q alert display on finl inspection 687_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All parts |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | OK |