QFR No - 7001085484
Defect Details
| NC No. | 7001085484 |
| NC Date | 26/12/2024 |
| NC Submission Date | |
| Part No. | B2GQ01903O |
| Part Name | MASTER CYLINDER RAW CASTING- C101 H |
| Supplier Name & Code | 101180-MAULI CAST TECH PVT. LTD |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | DIMENSSIONAL DEFECT-Pocket ID undersize |
1. Problem Description
| Defect Description | Pocket ID Oversize |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 1008 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | qlasf0aite00ai1he1jwotfc.jpg |
Supplier Communication Details
| Quality Head Email ID | quality@maulicasttech.com |
| Plant Head/CEO Email ID | planthead@maulicasttech.com |
| MD Email ID | shrikant.shelke@maulimetal.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1008
|
0
|
0
|
0
|
2508
|
3516
|
| Check Qty |
1008
|
0
|
0
|
0
|
2508
|
3516
|
| NG Qty |
1008
|
0
|
0
|
0
|
0
|
1008
|
| Scrap | 0 |
| Rework | 1008 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1.ETL End – 1008 Qty 2.Available stock at Supplier end 100% verification started for Dimn 28 & 46 (2508 no’s in WIP At MCTPL End) 3.Awareness given to all concern person with Q alert. 4.100% gauges inspection started at final inspection stage with Dot marking. 5.Provided gauge & 100% inspection started at final inspection stage. |
3. Process Flow
| Process Flow Description |
|---|
| Raw material Receipt & Inspection of Alloy - Raw Material Storage -Melting of Aluminum Alloy -Gravity Die Casting -Gate & Riser cutting-Lancering-Fettling -Heat Treatment -T6-Shot Blasting-Tracebility -Final Visual Inspection-Pre- Dispatch Inspection -Packing & Dispatch . |
4. Process Details
| Process / Operation | GDC OPERATION |
| Outsource | No |
| Machine / Cell | GDC MACHINE |
| Machine / Cell No. | GDC MACHINE -14 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Loose insert dimension is in lower side due to Pocket punch wear out during running. | After recheck the part dimension found in lower side. | X |
| Tool | Pocket punch wear out | Pocket punch wear out due to frequent polishing on punch surface Punch Wear out By 0.020 mm to 0. | X |
| Man | Skipped from in process inspection. | nspector checked as per drawing by vernier and not detected 20 micron variation by VC | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Found go gauge not passing in RFD part _Dimn. 46+0.2-DR and 28+0.2-DR Under size |
| Why 2 | Go gauge Not passing completely |
| Why 3 | Pocket Dimn found under size by 0.020 to 0.040 mm. |
| Why 4 | Pocket punch wear out during running ( Wear out by 10400 shots). |
| Why 5 | Tool wear out early as decided tool life due to Pocket punch wear out due to frequent polishing on punch surface . |
| Root Cause (Occurance) | Tool wear out early as decided tool life due to Pocket punch wear out due to frequent polishing on punch surface . |
Root Cause Analysis (Outflow)
| Why 1 | Skipped from in process inspection . |
| Why 2 | Dimn. checked but not detected by 10 to 20 micron during inspection. |
| Why 3 | This dimn. checked by vernier . |
| Why 4 | This is pocket profile dimn. So Inspection method is wrong -because dimn. checked by vernier . |
| Why 5 | |
| Root Cause (Outflow) | 10 to 20 micron not detected during in process inspection . |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1.Die life monitoring started and Punch life to be fixed ( Now Tool life decided 10400 shots ). 2.New punch to be procured for maintaining min max stock. | Pradip Benurkar. | 31/01/2025 | 07/01/2025 | Completed |
| Outflow | 1.Provided gauge & 100% inspection started at final inspection stage. 2.This pocket Dimn. Check by profile gauge during in process inspection & setup. | Nadeem Shaikh | 24/12/2024 | 24/12/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Provided gauge & 100% inspection started at final inspection stage and This pocket Dimn. Check by profile gauge during in process inspection & setup. |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Go gauge Not passing completely.
Pocket punch wear out due to frequent polishing on punch surface 1293_Occurance_Before.pptx |
| Occurance (After) |
1.Tool/punch life monitoring started and Punch life to be fixed (Now Punch life decided is 10400 shots ).
2. New punch to be procured for maintaining min max stock 1293_Occurance_After.pptx |
| Outflow (Before) |
Inner pocket dimn. 46+0.2-DR and 28+0.2-DR found not ok (Under size, pocket gauge not passing completely, All 4 cavity)- 1293_Outflow_Before.png |
| Outflow (After) |
1. Provided gauge & 100% inspection started at final inspection stage.
2.This Dimn. Check by special profile gauge during setup & in-process inspection. 1293_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | TVS FRONT MASTER CLY. |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, InspCheckSheet |
| Specify Other Document | Tool life sheet |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |