QFR No - 8000785862
Defect Details
| NC No. | 8000785862 |
| NC Date | 30/04/2022 |
| NC Submission Date | |
| Part No. | 16JPP00117 |
| Part Name | WHEEL CLUTCH REML 6 PLATE / 7 PLATE |
| Supplier Name & Code | 100656-MADHURA DIE CAST PVT.LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | CRACK-LUG CRACK |
1. Problem Description
| Defect Description | Crack |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 2 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | madhuradiecast@gmail.com |
| Plant Head/CEO Email ID | madhuradiecast@gmail.com |
| MD Email ID | madhuradiecast@gaikegroup.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
500
|
0
|
0
|
200
|
300
|
1000
|
| Check Qty |
500
|
0
|
0
|
200
|
300
|
1000
|
| NG Qty |
2
|
0
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Stock Segregation done at the Customer end, supplier end with blue dot marking on lug side. |
3. Process Flow
| Process Flow Description |
|---|
| 1.Casting 2.fetling 3. CNC 1st Set-up 4.CNC 2nd Set-up 5.Drilling & Tapping 6.Final Inspection |
4. Process Details
| Process / Operation | Casting |
| Outsource | No |
| Machine / Cell | PDC 400T |
| Machine / Cell No. | 04 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskill Operator On machine. | Skill Matrix Varified & Found OK. | O |
| Tool | Die Blue Matching not Done. | Found Not ok | X |
| Machine | Water Was Leakage in Die | Checking water leakage & Found Ok. | O |
| Material | Degassing was not done on decide frequency. | Melting cum furnace degassing report verified & found ok. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
7. Root Cause Analysis (Occurance)
| Why 1 | Crack Observed on Lug |
| Why 2 | Crack is Generated because of cold shot |
| Why 3 | Die was Flashing |
| Why 4 | Blue Matching not done |
| Why 5 | |
| Root Cause (Occurance) | Blue Matching not done |
Root Cause Analysis (Outflow)
| Why 1 | Crack Observed on Lug |
| Why 2 | NG Component Was mixed with ok component. |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | NG Component Was mixed with ok component. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 1 Tagging to all bin 2 Rejection and ok component area are define 3 Lock and key rejection bin wii be implement | Quality Superviser | 20/05/2022 | 11/07/2022 | Completed |
| Occurance | 1 Die Blue matching done. 2 OPL Displayed on casting stage. | Production Superviser | 19/05/2022 | 18/07/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | This defect is monitoring on Q Gate. started 200% Inspection with identification marking |
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
Blue Matching not done 81_Occurance_Before.jpeg |
| Occurance (After) |
1 Die Blue matching done. 2 OPL Displayed on casting stage. 81_Occurance_After.jpeg |
| Outflow (Before) |
NG Component Was mixed with ok component. 81_Outflow_Before.jpeg |
| Outflow (After) |
1 Tagging to all bin 2 Rejection and ok component area are define 3 Lock and key rejection bin wii be implement 81_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | no |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | QA OPL |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |