QFR No - 7001048728
Defect Details
| NC No. | 7001048728 |
| NC Date | 31/08/2024 |
| NC Submission Date | |
| Part No. | 520AE00300 |
| Part Name | CORE PLATE 3W 4S |
| Supplier Name & Code | 100959-AAR CEE ENGINEERING WORKS UNIT |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | CRACK-heavy nonfelling , buckling & crack issu |
1. Problem Description
| Defect Description | Major Casting defect observed at lot i.e Non filling ,Casting crack & Casting Bend/Buckling |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 25000 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qc@aarceeengg.com |
| Plant Head/CEO Email ID | planthead.diecasting@aarceeengg.com |
| MD Email ID | vaibhav.arora@aarceeengg.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
25000
|
15000
|
20000
|
0
|
0
|
60000
|
| Check Qty |
25000
|
15000
|
20000
|
0
|
0
|
60000
|
| NG Qty |
5000
|
0
|
0
|
0
|
0
|
5000
|
| Scrap | 5000 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Material segregation with identification |
3. Process Flow
| Process Flow Description |
|---|
| 1)raw material receipt 2)Storage of Raw Material3)Holding Cum Melting 4) PDC 5) 1st trimming 6) Shot Blasting for burr removing 7)Final Inspection & Packing 8) Stress Relieving 9)Sound Testing10)Shot Blasting 11)Barreling12)2nd Trimming |
4. Process Details
| Process / Operation | pdc |
| Outsource | No |
| Machine / Cell | hpdc |
| Machine / Cell No. | 8 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | lack of experience /training | New inspector | X |
| Method | insufficient hydraulic fluid flow rate | After verification hydraulic pressure found drop | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 125 |
7. Root Cause Analysis (Occurance)
| Why 1 | Non filling in Core Plate |
| Why 2 | Intensification pressure improper |
| Why 3 | hydraulic pressure drop |
| Why 4 | hydraulic valve malfunction |
| Why 5 | insufficient hydraulic fluid flow rate |
| Root Cause (Occurance) | insufficient hydraulic fluid flow rate |
Root Cause Analysis (Outflow)
| Why 1 | Non filling in Core Plate |
| Why 2 | Improper inspection by final inspectors |
| Why 3 | lack of experience /training |
| Why 4 | New inspector |
| Why 5 | |
| Root Cause (Outflow) | Training provide to new operators Limit samples will be displayed for better understand. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1. Check hydraulic Fluid level and condition on daily basis 2.W.I has been updated for hydraulic oil tank level 3 Training Provided to the Operator . 4 Valve maintenance check point added in pm check list 5 hydraulic level monitoring on daily basis | HIMANSHU | 02/09/2024 | 03/09/2024 | Completed |
| Outflow | start on job training on daily basis poison test started 100% marking has been Implemented on Outside of the Bunch | HIMANSHU | 02/09/2024 | 03/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | visuals defects checked magnifying glass |
| Inspection Method | Other |
| Other Inspection Method | visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
10. Evidance of Countermeasure
| Occurance (Before) |
1) valve condition not checked before
2)Hydraulic level not monitoring on daily basis 1054_Occurance_Before.xls |
| Occurance (After) |
1. Check hydraulic Fluid level and condition on daily basis
2.W.I has been updated for hydraulic oil tank level
3 Training Provided to the Operator
. 4 Valve maintenance check point added in pm check list
5 hydraulic level monitoring on daily basis 1054_Occurance_After.xls |
| Outflow (Before) |
LACK OF TRANING 1054_Outflow_Before.xls |
| Outflow (After) |
DEFECT awareness training increase & poison test adequate
100% marking has been Implemented on Outside of the Bunch 1054_Outflow_After.xls |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | ,LML REDUCED,K-70,K1&K2 |
12. Document Review
| Documents | WISOP |
| Specify Other Document | traning plan |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Actions not updated Recurrence of defect phenomenon (No sustenance monitored ) RCA need revisit |