QFR No - 8000786469
Defect Details
| NC No. | 8000786469 |
| NC Date | 06/05/2022 |
| NC Submission Date | |
| Part No. | C2FY00233M |
| Part Name | HUB CL. WITH INSERT MACHINED-D1 |
| Supplier Name & Code | 100874-ANUSHRUSHTI AUTO PARTS |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | RUN OUT MORE-TEETH R/O O/S UP TO 0.40 MM |
1. Problem Description
| Defect Description | Teeth OD Run out observed upto 0.4 mm as against 0.25 mm |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 25 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@anushrushtiautoparts.com |
| Plant Head/CEO Email ID | anushrushti2011@rediffmail.com |
| MD Email ID | rrwable@redffmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
300
|
0
|
0
|
0
|
0
|
300
|
| Check Qty |
300
|
0
|
0
|
0
|
0
|
300
|
| NG Qty |
25
|
0
|
0
|
0
|
0
|
25
|
| Scrap | 25 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% inspection done for D1 HUB CL WITH INSERT with marking on TEETH. |
3. Process Flow
| Process Flow Description |
|---|
| 1.)RM INWARD 2) CNC 1ST SETUP 3) CNC 2ND SETUP 4) DRILLING 5)FINAL INSPECTION 6) PACKING & DISPATCH |
4. Process Details
| Process / Operation | CASTING |
| Outsource | Yes |
| Machine / Cell | CNC 2 |
| Machine / Cell No. | CNC 2 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Inspector not aware of defect | Inspector skill matrix checked found ok | O |
| Man | Operator not aware of defect | Operator training was not effective | X |
| Method | Separate bins not used for storage | Operator is storing Parts in special partision bin | O |
| Method | Part clamping & decampling not proper | uneven part clamping in jaw | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | MANDRELL& DIAL GAUGE |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5NO`S /LOT |
7. Root Cause Analysis (Occurance)
| Why 1 | uneven part clamping in jaw |
| Why 2 | heavy burr deposited at part clamping location (jaw) |
| Why 3 | part clamping location not clean properly |
| Why 4 | part clamping location cleaning frequency not define properly. |
| Why 5 | |
| Root Cause (Occurance) | part clamping location cleaning frequency not define properly. |
Root Cause Analysis (Outflow)
| Why 1 | Part inspection frequency not evident |
| Why 2 | Lot wise 5 no`s inspection fequency was define in control plan |
| Why 3 | |
| Why 4 | Part inspection frequency not evident |
| Why 5 | |
| Root Cause (Outflow) | Part inspection frequency not evident |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Partwise On job training are provided of all operator | Mr.Malhari pawar | 18/05/2022 | 18/05/2022 | Completed |
| Outflow | Part inspection frequency not evident | Deepak singh | 27/05/2022 | 27/05/2022 | Completed |
| Occurance | part clamping location cleaning frequency not define properly | malhari pawar | 16/06/2022 | 16/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 1)Before - 5no`s per lot inspection done 2) After customer complaints -per bins 1 nos inspection started in final inspection |
| Inspection Method | Other |
| Other Inspection Method | dial+centerbetween |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | PER BINS 1 |
10. Evidance of Countermeasure
| Occurance (Before) |
Jaw Burr cleaning frequency not define in control plan 95_Occurance_Before.xlsx |
| Occurance (After) |
Jaw Burr cleaning define & updated in controlplan 95_Occurance_After.xlsx |
| Outflow (Before) |
Face runout insp frequency was 5 no`s per lot 95_Outflow_Before.xlsx |
| Outflow (After) |
Face runout insp frequency revied from 5 no`s per lot to 1 no`s per Bins 95_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Tranmission Division |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | On job training shee |
13. Effectiveness Of Action
| Reviewed Quantity | 2000 |
| Reason for submission | OK |