QFR No - 8000785385
Defect Details
| NC No. | 8000785385 |
| NC Date | 26/04/2022 |
| NC Submission Date | |
| Part No. | 530CZ00102 |
| Part Name | DU BUSH |
| Supplier Name & Code | 100037-BBL DAIDO PRIVATE LIMITED |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | CHAMFER NOT DONE- WARRANTY ANALYSIS PART |
1. Problem Description
| Defect Description | Uneven Chamfer and ID Coating Crumble observed in Warranty Return Parts, Also witnessed to supplier person. |
| Detection Stage | Warranty |
| Problem Severity | Function |
| NG Quantity | 5 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | rajamani@bbldaido.com |
| Plant Head/CEO Email ID | vinod@bbldaido.com |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5
|
0
|
0
|
0
|
0
|
5
|
| Check Qty |
5
|
0
|
0
|
0
|
0
|
5
|
| NG Qty |
5
|
0
|
0
|
0
|
0
|
5
|
| Scrap | 5 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Bush investigated and found ID chamfer found OK and Bush material PTFE composition found good , hence Oil leak is not related to DU Bush. Available Bush at BBLD found OK |
3. Process Flow
| Process Flow Description |
|---|
| RM Inspection - Slitting - Welding - Size rolling - Facing and chamfering -Pressing - Coining - Plating - Final Inspection - Despatch |
4. Process Details
| Process / Operation | Facing and chamfering |
| Outsource | No |
| Machine / Cell | Bush Manufacturing line |
| Machine / Cell No. | 5B-2 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | ID Chamfer one side tool less depth of cut | Less depth of cut | 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 | 20 nos per |
7. Root Cause Analysis (Occurance)
| Why 1 | ID Chamfer one side tool less depth of cut |
| Why 2 | Coil Feed to chamfering tool contact space less |
| Why 3 | Chamfer coil movement waviness not consider to run the parts maximum side |
| Why 4 | Control dimension not provided in the process drawing |
| Why 5 | |
| Root Cause (Occurance) | Control dimension not provided in the process drawing |
Root Cause Analysis (Outflow)
| Why 1 | Bush ID chamfer found NG |
| Why 2 | Bush ID chamfer sampling ( 1 no per lot) inspection by contour |
| Why 3 | Sampling not adequate to control the ID chamfer dimension |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Sampling not adequate to control the ID chamfer dimension |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1.Control dimension not provided in the process drawing | T.Rajamani | 05/05/2022 | 05/09/2022 | Completed |
| Outflow | Visual inspection limit sample provided to check the less chamfer | T.Rajamani | 05/05/2022 | 05/09/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | ID chamfer band modified as per customer required chamfer |
| Inspection Method | Other |
| Other Inspection Method | ID chamfer provided |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 20 |
10. Evidance of Countermeasure
| Occurance (Before) |
Refer attached 77_Occurance_Before.pdf |
| Occurance (After) |
Refer attached 77_Occurance_After.pdf |
| Outflow (Before) |
Refer attached 77_Outflow_Before.pdf |
| Outflow (After) |
Refer attached 77_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Not applicable |
12. Document Review
| Documents | PFMEA, InspCheckSheet |
| Specify Other Document | Process drawing |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |