QFR No - 8000783465
Defect Details
| NC No. | 8000783465 |
| NC Date | 11/04/2022 |
| NC Submission Date | |
| Part No. | 520AE00200 |
| Part Name | CORE PLATE K1 & K2 |
| Supplier Name & Code | 100959-AAR CEE ENGINEERING WORKS UNIT |
| ETL Plant | 1135-ETL 7/10 P Nagar |
| Defect Details | SURFACE FINISH NOT OK-RA VALUE LESS THAN 2RA |
1. Problem Description
| Defect Description | Shot Blasting not done on one side of Plates. its Ra value observed as 1.38,1.36,1.39,1.42,1.48 against the minimum specification of 2 to 3 Ra |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 32 |
| 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 |
5000
|
0
|
0
|
2000
|
0
|
7000
|
| Check Qty |
5000
|
0
|
0
|
2000
|
0
|
7000
|
| NG Qty |
32
|
0
|
0
|
10
|
0
|
42
|
| Scrap | 0 |
| Rework | 42 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All materials are segregated at the customer end (ETL end) as well as supplier FG (AAR CEE end). NG pieces re-shot blasting to be done. |
3. Process Flow
| Process Flow Description |
|---|
| 10. Receipt of Raw Material 20. Storage of Raw Material 30. Holding Cum Melting 40. PDC 50. Trimming 60. Shot Blasting 70. Barrelling 80. Sound Testing 90. Stress Relieving 100. Final Inspection & Packing 110. Storage & Dispatch |
4. Process Details
| Process / Operation | 60. Shot Blasting |
| Outsource | No |
| Machine / Cell | Shot Blasting Machine |
| Machine / Cell No. | SBM-02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | In Shot Blasting Machine one side liner got broken suddenly | One side liner found broken in Shot Blasting Machine | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 pieces |
7. Root Cause Analysis (Occurance)
| Why 1 | Ra value found less than 2 Ra due to one side liner getting broken suddenly in the shot blasting machine. |
| Why 2 | Operator not aware of such kind of issue |
| Why 3 | The operator was not aware, there was no checkpoint on the check sheet for the shot blasting machine liner |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | There was no checkpoint in the check sheet for the shot blasting machine liner. |
Root Cause Analysis (Outflow)
| Why 1 | Ra value found less than 2 Ra due to Ra value check at two places of the core plate |
| Why 2 | Quality Person not aware of the same |
| Why 3 | There was no method defined to check the Ra value on the core plate |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | There was no method defined to check the Ra value on the core plate |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Check point for liner inspection to be added in check sheet | Ankit Gupta | 21/04/2022 | 21/04/2022 | Completed |
| Outflow | Ra value checking method to be defined in control plan, PFEMA & inspection report | Ankit Gupta | 21/04/2022 | 21/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Ra value to be checked in process at 4 places of the core plate instead of 2 places |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 pieces |
10. Evidance of Countermeasure
| Occurance (Before) |
Check sheet before adding the checkpoint for liner 48_Occurance_Before.pdf |
| Occurance (After) |
Check sheet after adding the checkpoint for liner 48_Occurance_After.pdf |
| Outflow (Before) |
Inspection report before defining the method to check the Ra value 48_Outflow_Before.pdf |
| Outflow (After) |
Inspection report after defining the method to check the Ra value 48_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All model core plates |
12. Document Review
| Documents | ControlPlan, PFMEA, JHCheckSheet, InspCheckSheet |
| Specify Other Document | No other documents |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |