QFR No - 7001055337
Defect Details
| NC No. | 7001055337 |
| NC Date | 19/09/2024 |
| NC Submission Date | |
| Part No. | 520AE00400 |
| Part Name | CORE PLATE REDUCED 612 |
| Supplier Name & Code | 100959-AAR CEE ENGINEERING WORKS UNIT |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | NON FILLING-Non Felling ,Blow Hole |
1. Problem Description
| Defect Description | Heavy Non filling ,Blow Hole & crack observed |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 416 |
| 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 |
416
|
5000
|
10000
|
0
|
0
|
15416
|
| Check Qty |
416
|
5000
|
10000
|
0
|
0
|
15416
|
| NG Qty |
416
|
0
|
0
|
0
|
0
|
416
|
| Scrap | 416 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All available stock will be quarantine and seggrigation100% |
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 | CASTING |
| Outsource | Yes |
| Machine / Cell | HPDC |
| Machine / Cell No. | 7 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Trapped air in the mold or die cavity. | Air entrapment | X |
| Man | Improper Inspection | Inspection not done properly | 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 | Air entrapment |
| Why 2 | turbulent metal flow |
| Why 3 | inadequate gas removal |
| Why 4 | Dissolved gases in molten metal ( nitrogen) |
| Why 5 | higher temps increase gas solubility |
| Root Cause (Occurance) | higher temps increase gas solubility |
Root Cause Analysis (Outflow)
| Why 1 | Blow hole in core plate |
| Why 2 | Human error |
| Why 3 | Lack of attention or focus |
| Why 4 | Lack of training or experience |
| Why 5 | |
| Root Cause (Outflow) | Lack of training or experience |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1. Optimize temperature control. 2.W.I has been updated for temperature control. 3.Training Provided to the Operator. 4)monitor and control casting temperature | ANIRUDH/RITIK | 23/09/2024 | 23/09/2024 | Completed |
| Occurance | 1.Regular training and refresher courses 2. Performance monitoring and feedback(poision test) 3.Q-Sustenance monitoring Check sheet has been Implemented. 4. Quality Inspector initial marking done on each & every piece. | Nishant | 22/09/2024 | 22/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | no |
| Inspection Method | Other |
| Other Inspection Method | visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 125 |
10. Evidance of Countermeasure
| Occurance (Before) |
Temperature inspection frequency less in process inspection report 1104_Occurance_Before.xls |
| Occurance (After) |
1. Optimize temperature control.
2.Training Provided to the Operator.
3)monitor and control casting temperature 1104_Occurance_After.xls |
| Outflow (Before) |
Inadequate inspector performance monitoring 1104_Outflow_Before.xls |
| Outflow (After) |
1.Regular training and refresher courses
2. Performance monitoring and feedback(poision test)
3.Q-Sustenance monitoring Check sheet has been Implemented.
4. Quality Inspector initial marking done on each & every piece. 1104_Outflow_After.xls |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | k70,3w4s |
12. Document Review
| Documents | WISOP, InspCheckSheet |
| Specify Other Document | dock audit |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | Ok |