QFR No - 8000787195
Defect Details
| NC No. | 8000787195 |
| NC Date | 11/05/2022 |
| 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 | THREADING MISSING-THREADING MISSING & O/S ISSUE |
1. Problem Description
| Defect Description | Thread missing to all six lugs |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| 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 |
800
|
0
|
0
|
550
|
330
|
1680
|
| Check Qty |
800
|
0
|
0
|
550
|
330
|
1680
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1.100% All material segregation at customer end and inhouse end with identification blue marking on the lug. 2. Started operator traceability by initial of operator name mentioned on the component. |
3. Process Flow
| Process Flow Description |
|---|
| 1.Casting 2.fetling 3. CNC 1st Set-up 4.CNC 2nd Set-up 5.VMC (6 Hole drilling and tapping) 6.Final Inspection |
4. Process Details
| Process / Operation | VMC (6 Hole drilling and tapping) |
| Outsource | No |
| Machine / Cell | VMC |
| Machine / Cell No. | VMC NO.01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Input & output material bin not identified on drilling tapping stage | Drilling tapping stage checked found not ok | X |
| Man | Unskill operator operate machine | Skill matrix verify found ok | O |
| Machine | Component was Rest wrong position | fixture checked not possiblity to rest wrongly | O |
| Tool | Wrong grade drill and tapp used for operation | Checked and verify found ok | O |
| Material | Double drilling and tapping done on component | Component checked found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10/Hr |
7. Root Cause Analysis (Occurance)
| Why 1 | Threading missing -Threading missing and O/s. |
| Why 2 | Drilling and tapping was not done on component. |
| Why 3 | Without drilling and tapping component mix with ok components. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Without drilling and tapping component mix with ok components. |
Root Cause Analysis (Outflow)
| Why 1 | Threading missing -Threading missing and O/s. |
| Why 2 | TPG Checking done was sampling basis. |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | TPG Checking done was sampling basis. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1. Input material and output material Bin identified. 2. We change final inspection table location from away drilling tapping operation. 3. Started operator traceability by initial name mentioned on component & marking on Lug conformation of Threading operation done | Production Supervisor | 14/05/2022 | 12/05/2022 | Completed |
| Outflow | 1. Started 100% Thread plug gauging checking and marking on the lug for gauging conformation. 2.QA alert & OPL , Displayed on final inspection table. 3. Defective sample displayed at final inspection table. | QA Supervisior | 12/05/2022 | 12/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Started 100% Thread plug gauging checking. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
Without drilling and tapping component mix with ok components.2. Input material and output material Bin not identified. 111_Occurance_Before.jpeg |
| Occurance (After) |
1. Input material and output material Bin identified. 2. We change final inspection table location from away drilling tapping operation. 3. Started operator traceability by initial name mentioned on component & marking on Lug conformation of Threading operation done 111_Occurance_After.pdf |
| Outflow (Before) |
TPG Checking done was sampling basis. 111_Outflow_Before.jpeg |
| Outflow (After) |
1. Started 100% Thread plug gauging checking and marking on the lug for gauging conformation. 2.QA alert & OPL , Displayed on final inspection table. 3. Defective sample displayed at final inspection table. 111_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NO |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | Q-Alert,OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Analysis not proper -Input output material handling system should specify with color ,bins / trolleys type etc. for easily distinguish the parts |