QFR No - 8000783879
Defect Details
| NC No. | 8000783879 |
| NC Date | 14/04/2022 |
| NC Submission Date | |
| Part No. | 580DL54702 |
| Part Name | FTL HUB CLUTCH VAVE 4 PLATE |
| Supplier Name & Code | 205400-NAMO SAI INDUSTRIES |
| ETL Plant | 1135-ETL 7/10 P Nagar |
| Defect Details | BLOW HOLES-BLOW HOLE & OTHER CASTING DEFECTS |
1. Problem Description
| Defect Description | Blow Holes & Multiple Pin Holes on the Insert Back face & in ID of Hub Vave, Rejection %age increased up to 29%, Till Date no rigid Action taken for the prevention & Reduction of same. |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 720 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | namosaiindustries@gmail.com |
| Plant Head/CEO Email ID | namosaiindustries@gmail.com |
| MD Email ID | mansingh@namosaiindustries.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1500
|
0
|
0
|
1000
|
400
|
2900
|
| Check Qty |
1500
|
0
|
0
|
1000
|
400
|
2900
|
| NG Qty |
720
|
0
|
0
|
10
|
0
|
730
|
| Scrap | 720 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Parts are check and putted the identification marks |
3. Process Flow
| Process Flow Description |
|---|
| PDC |
4. Process Details
| Process / Operation | PDC |
| Outsource | No |
| Machine / Cell | PDC Machine |
| Machine / Cell No. | PDC Machine |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Machine Parameters | Water Pressure less | X |
| Tool | Problem in Machine Die | Gasses not release properly | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | No Method |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 1 |
7. Root Cause Analysis (Occurance)
| Why 1 | Below hole observed after machining |
| Why 2 | Less water presser in die |
| Why 3 | Less water pressure generate from pump |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Less water pressure generate from pump |
Root Cause Analysis (Outflow)
| Why 1 | Below hole observed after machining |
| Why 2 | Gasses not release during die casting |
| Why 3 | No provision for gasses release in Die |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No provision for gasses release in Die |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Booster pump added to increase the water pressure | Namo Sai | 20/10/2022 | 20/10/2022 | Completed |
| Outflow | One Piece cut every one hrs to check the blow hole | Namo Sai | 20/10/2022 | 20/10/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | One Piece cut every one hrs to check the blow hole |
| Inspection Method | Other |
| Other Inspection Method | Cut Piece Visual |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 1 |
10. Evidance of Countermeasure
| Occurance (Before) |
Pump Before 53_Occurance_Before.jpg |
| Occurance (After) |
Pump After 53_Occurance_After.jpg |
| Outflow (Before) |
Die Before 53_Outflow_Before.jpg |
| Outflow (After) |
Die After 53_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All PDC Machine |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | OK |