QFR No - 7001018209
Defect Details
| NC No. | 7001018209 |
| NC Date | 29/05/2024 |
| NC Submission Date | |
| Part No. | 520FN04002 |
| Part Name | HOLDER CLUTCH |
| Supplier Name & Code | 101138-HINDUSTAN PRESSINGS PVT.LTD. |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | DIMN.O/SIZE.-dimn 2.96 ~3.14 u/s & o/s against 3+0.1 |
1. Problem Description
| Defect Description | Bearing Resting Height found undersize & Oversize up to 2.96~3.14 mm against 3±0.1 |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 300 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
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 |
300
|
0
|
0
|
0
|
500
|
800
|
| Check Qty |
300
|
0
|
0
|
0
|
500
|
800
|
| NG Qty |
300
|
0
|
0
|
0
|
0
|
300
|
| Scrap | 0 |
| Rework | 300 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Visit to customer end and witness the quality issue. |
3. Process Flow
| Process Flow Description |
|---|
| 1)Blaking And piercing 2)Sandering 3)Chamfer 4)machining 5)Final inspection and packeging 6)PDIR and Dispatch |
4. Process Details
| Process / Operation | Machining |
| Outsource | Yes |
| Machine / Cell | CNC machine |
| Machine / Cell No. | Machine no-1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | THICKNESS VARIATION MAY CAUSE HEIGHT ISSUE DURING MACHING STAGE | 100% GAP GAUGE SHOULD BE DONE TO SEGRIGATE THE PARTS, ACCODING TO THCKINESS, WHICH HELPS TO MACHININ | X |
| Tool | DAMAGED TOOL USED | TOOL CONDITION WAS OK. | O |
| Machine | MACHINING NOT DONE PROPERLY | MACHINING DONE PROPERLY | O |
| Man | POOR MATERIAL HANDLING&DURING INPROCESS, INSPECTION. | THERE WAS NO PROPER METHOD TO CHECK PART THICKNESS INDIDUALLY | X |
| Method | RAW MATERIAL THICKNESS USED TO CHECK AT SAMPLE BASIS AT RECEIVING STAGE | AFTER BLANKING STAGE VARIATION IN THICKNESS THAT WAS UNDER TOLERENCE | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Thickness variation in part is causing height issue at machining stage. |
| Why 2 | height dimension checking being done on sample basis. |
| Why 3 | gap gauge was not using for to identify thckiness variation parts. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Due to thickness variation in parts causing height issue at maching stage |
Root Cause Analysis (Outflow)
| Why 1 | Bearing Resting Height found undersize & Oversize up to 2.96~3.14 mm against 3±0.1 |
| Why 2 | Defect found at ETL at recipt stage. |
| Why 3 | defect causing fitment issue at assembly line |
| Why 4 | Sample basis inspection done by final inspector but defect not detected. |
| Why 5 | less awareness to inspector regarding depth checking with dail gauge. |
| Root Cause (Outflow) | less awareness to inspector regarding height issue and how to check properly. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Before sending to machining 100 % gap gauge is must done. So that we can seggrigate thickness variation parts to avoid further height issue.. | Mr. Hitendra Patil and Mr, Ningaraj S | 21/06/2024 | 21/06/2024 | Completed |
| Occurance | Awareness given to the inspectors regarding height issue. | Mr.Kiran W | 21/06/2024 | 21/06/2024 | Completed |
| Outflow | 1. Training given to inspectors regarding all final inspection activities of 4002 holder,specially focussing on height issue. 2. 100% inspection at HPPL pune from QA person for next 3 lot | Mr.Ningaraj S( HPPL) | 21/06/2024 | 21/06/2024 | Completed |
| Occurance | Work instruction of RM checking updated for the thickness variation acceptance. | Mr Kiran | 21/06/2024 | 21/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Before Machining proce we do the gap gauge inspection. |
| 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) |
Work instruction of RM inspection. 830_Occurance_Before.pdf |
| Occurance (After) |
Work instruction for RM checking to b updated as per the thickness. 830_Occurance_After.pdf |
| Outflow (Before) |
We have not implemented the gap gauge for checking. 830_Outflow_Before.pdf |
| Outflow (After) |
We check with gap gauge before sending to maching. 830_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | No |
12. Document Review
| Documents | ControlPlan, WISOP |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | OK |