QFR No - 8000787196
Defect Details
| NC No. | 8000787196 |
| NC Date | 11/05/2022 |
| NC Submission Date | |
| Part No. | 520FW04702 |
| Part Name | CLUTCH HOUSING FULL FINISHED-K70 |
| Supplier Name & Code | 100656-MADHURA DIE CAST PVT.LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | OPERATION MISSING-2ND SETUP M/C OPERATION MISSING |
1. Problem Description
| Defect Description | 2ND SETUP MACHINING OPERATION MISSING |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| 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 |
2000
|
0
|
0
|
2500
|
1500
|
6000
|
| Check Qty |
2000
|
0
|
0
|
0
|
0
|
2000
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1.100% Stock segregate at customer end and Supplier end stock. |
3. Process Flow
| Process Flow Description |
|---|
| 1.Casting 2.fetling 3. CNC 1st Set-up 4.CNC 2nd Set-up 5.Final Inspection |
4. Process Details
| Process / Operation | CNC 2nd Set-up |
| Outsource | No |
| Machine / Cell | JE/CNC NO.02 |
| Machine / Cell No. | JE/CNC NO.02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Component was skipped from 2nd side Cnc operation | verify and checked found ok | O |
| Man | Unskill operator loading the vechicle | verify found not ok | X |
| Method | Component was mix up on loading stage | Loading person not aware about part operation | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | 100% Visual checking |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
7. Root Cause Analysis (Occurance)
| Why 1 | 2nd side missing component was a mix-up with ok component |
| Why 2 | Vehicle loading operator is was put not ok component to ok bin because one component is required for fulfilling the bin |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | The vehicle loading operator was put not ok component to the ok bin because one component is required for fulfilling the bin. |
Root Cause Analysis (Outflow)
| Why 1 | Final inspector not put tag in ok component bin |
| Why 2 | Unskill inspector |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Unskill inspector |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1. Awareness was created about the defect in the Loading operator. 2. Don`t put the component ready for the dispatch bin without the permission of the dispatch supervisor. 3. Ready for dispatch tag put in the bin for confirmation of ok part for dispatch. | Dispatch Supervisior | 15/05/2022 | 16/05/2022 | Completed |
| Outflow | 1. Training and awareness are given to the final inspector. 2. Cross verify by Dispatch component by the inspector before loading the vehicle. | QA Engineer | 12/05/2022 | 13/05/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Cross verify by Dispatch component by the inspector before loading the vehicle. |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
The vehicle loading operator was put not ok component to the ok bin because one component is required for fulfilling the bin. 106_Occurance_Before.jpeg |
| Occurance (After) |
1. Awareness was created about the defect in the Loading operator. 2. Don`t put the component ready for the dispatch bin without the permission of the dispatch supervisor. 3. Ready for dispatch tag put in the bin for confirmation of ok part for dispatch. 106_Occurance_After.pdf |
| Outflow (Before) |
Final inspector not put tag in ok component bin 106_Outflow_Before.jpeg |
| Outflow (After) |
1. Training and awareness are given to the final inspector. 2. Cross verify by Dispatch component by the inspector before loading the vehicle. 106_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | ALL ETL COMPONENT |
12. Document Review
| Documents | PFMEA, InspCheckSheet |
| Specify Other Document | QA OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Analysis not proper |