QFR No - 7001062684
Defect Details
| NC No. | 7001062684 |
| NC Date | 11/10/2024 |
| NC Submission Date | |
| Part No. | 530BU00302 |
| Part Name | Stricker Cap |
| Supplier Name & Code | 100144-AURANGABAD PRESSINGS |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | DIMETER UNDERSIZE-I/D U/SIZE SPE=43.60-0.30 GAUGE NOT PASS |
1. Problem Description
| Defect Description | DIMETER UNDERSIZE-I/D U/SIZE SPE=43.60-0.30 GAUGE NOT PASS |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 900 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@apw3.co.in |
| Plant Head/CEO Email ID | aurangabadpressings@apw3.co.in |
| MD Email ID | shashikant@apw3.co.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5139
|
0
|
0
|
0
|
2500
|
7639
|
| Check Qty |
5139
|
0
|
0
|
0
|
2500
|
7639
|
| NG Qty |
2511
|
0
|
0
|
0
|
1100
|
3611
|
| Scrap | 0 |
| Rework | 1700 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation all material |
3. Process Flow
| Process Flow Description |
|---|
| blanking+ piercing +forming Turning Notching +Dimpling Plating |
4. Process Details
| Process / Operation | Notching +Dimpling |
| Outsource | No |
| Machine / Cell | Press Shop |
| Machine / Cell No. | Machine No 9 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | Striker cap Mono m Dimn 43.6 -0.3 ID undersize up to 43.2 mm |
| Why 2 | Notch Depth oversize |
| Why 3 | Notch punch pressure excess |
| Why 4 | Dimple punch stroke is completed but of rod (cam) stroke stroke pressure is excess. |
| Why 5 | Rod (cam)punch Length more then Dimple punch |
| Root Cause (Occurance) | Dimple punch & rod (cam) Length maintain. . |
Root Cause Analysis (Outflow)
| Why 1 | Gauge Worn out Required 43.3 mm |
| Why 2 | Observed 43.25 |
| Why 3 | Worn-out |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Gauge checking fequriency not define |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Notching punch length excess | Deepak | 18/10/2024 | 21/10/2024 | Completed |
| Outflow | Gauge correction | P D Kulkarni | 18/10/2024 | 21/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection by Gauge |
| 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) |
Press shop 1141_Occurance_Before.pptx |
| Occurance (After) |
Quality 1141_Occurance_After.pdf |
| Outflow (Before) |
Press Shop 1141_Outflow_Before.pdf |
| Outflow (After) |
Inspection 1141_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Press shop |
12. Document Review
| Documents | ControlPlan, WISOP |
| Specify Other Document | WI |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |