QFR No - 8000785331
Defect Details
| NC No. | 8000785331 |
| NC Date | 26/04/2022 |
| NC Submission Date | |
| Part No. | 520FG00101 |
| Part Name | HELICAL GEAR K-70 |
| Supplier Name & Code | 100987-FLASH VIVEN MACHINING TECHNOLO |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | RUN OUT MORE-RUNOUT NOT OK,ID UNCLEAN |
1. Problem Description
| Defect Description | Runout Excess Upto 0.6 mm as against 0.15 mm |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 160 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | sgn.quality@flashgroup.in |
| Plant Head/CEO Email ID | dkj.mfg@flashgroup.in |
| MD Email ID | sv.md@flashgroup.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
3625
|
2000
|
2000
|
500
|
1500
|
9625
|
| Check Qty |
3625
|
2000
|
2000
|
500
|
1500
|
9625
|
| NG Qty |
81
|
0
|
0
|
12
|
23
|
116
|
| Scrap | 81 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Flatness checking at Final inspection stage Next 5 lots with Blue dot marking near bore Diameter. |
3. Process Flow
| Process Flow Description |
|---|
| CNC-Hobbing-HT-Bore honning-teeth honning-Final inspection-dispatch |
4. Process Details
| Process / Operation | HT |
| Outsource | No |
| Machine / Cell | heat treatment |
| Machine / Cell No. | ht |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Warpage | Visual | 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 | Bend Near ID location |
| Why 2 | Warpage near ID |
| Why 3 | Resting on outer face in stack of 5 parts in HT charge |
| Why 4 | No resting on counter face possibility of warpage |
| Why 5 | No provision |
| Root Cause (Occurance) | No resting on counter face possibility of warpage |
Root Cause Analysis (Outflow)
| Why 1 | Skip at Final QA |
| Why 2 | Sampling base inspection |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | 1) 100% Flatness checking at Final inspection stage Next 5 lots with Blue dot marking near bore Diameter. 2) OPL & Q Alert Displayed |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1. To provide spacer in between two parts to such that gear rest on plane face 2. Lower end provide Square type spacer in between charge & part | AGD | 30/06/2022 | 30/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 1) 100% Flatness checking at Final inspection stage Next 5 lots with Blue dot marking near bore Diameter. 2) OPL & Q Alert Displayed |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
10. Evidance of Countermeasure
| Occurance (Before) |
No resting on counter face possibility of warpage. 67_Occurance_Before.xlsx |
| Occurance (After) |
To provide spacer in between two parts to such that gear rest on plane face
Lower end provide Square type spacer in between charge & part 67_Occurance_After.xlsx |
| Outflow (Before) |
Sampling base inspection 67_Outflow_Before.xlsx |
| Outflow (After) |
100% Visual & Flatness checking at Final inspection stage Next 5 lots with Blue dot marking near bore Diameter. 67_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | JZ551400 & PF551402, DX551227 |
12. Document Review
| Documents | WISOP |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | OK |