QFR No - 8000787245
Defect Details
| NC No. | 8000787245 |
| NC Date | 12/05/2022 |
| NC Submission Date | |
| Part No. | 520FZ01002 |
| Part Name | HUB CLUTCH WITH INNER RING REML 6/7 PL |
| Supplier Name & Code | 101100-CAST 4 ALUMINIUM PVT LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | FITTMENT NOT OK.-Inner Ring Loose |
1. Problem Description
| Defect Description | Inner ring loose |
| Detection Stage | Warranty |
| Problem Severity | Function |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | info@cast4aluminium.com |
| Plant Head/CEO Email ID | info@cast4aluminium.com |
| MD Email ID | kiran@cast4aluminium.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Check Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| RM INWARD - MELTING - CASTING - GATE CUTTING & FETTLING - IN PROCESS INSPECTION - CNC MACHINING - RING PRESSING - BROACHING - OD GRINDING - FINAL INSPECTION - DISPATCH |
3. Process Flow
| Process Flow Description |
|---|
| RE-CHECK ALL PIPE LINE MATERIAL. |
4. Process Details
| Process / Operation | RING PRESSING |
| Outsource | Yes |
| Machine / Cell | PNEUMATIC PRESS MACHINE |
| Machine / Cell No. | PRESS MACHINE - 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Check point for bolt tight/loose in PM check sheet. | Observed no check point in PM check sheet. | X |
| Machine | Scaling not available for bolt setting of sensor | Observed no scaling on machine to set bolt. | X |
| Material | Ring ID not as per specification | Observed ring oversize. | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Pokayoke |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 NOS |
7. Root Cause Analysis (Occurance)
| Why 1 | Ring not pressed properly due to pressing loader setting disturbed. |
| Why 2 | Loader was shifted from the sensor face due to loose bolting. |
| Why 3 | Pressing loader travelling length gets disturb due to bolt loose tightening. |
| Why 4 | Scaling was not available to set bolt of sensor on machine. |
| Why 5 | No check point for bolt loose/tight in PM check sheet. |
| Root Cause (Occurance) | Scaling not available for bolt setting of sensor. |
Root Cause Analysis (Outflow)
| Why 1 | Inspector not able to judge loose ring press operation. |
| Why 2 | Part not detected in process validation. |
| Why 3 | Ring ID inspection was on sample basis 5 nos/lot. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Ring ID inspection was on sample basis 5 nos/lot |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1) Scaling provide to sensor setting on machine. 2) Check point added in PM check sheet and is monitored on daily basis. 3) Red colour coding implemented on setting piece rejection material. | Mr. Deepak Singh | 17/05/2022 | 17/05/2022 | Completed |
| Outflow | 1) Process validation done on daily basis. 2) 100% inspection for ring ID on air ring gauge. 3) Q-Alert displayed. 4) Training given to inspector and operator | Mr. Deepak Singh | 17/05/2022 | 17/05/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection for ring ID at inward inspection stage. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
No scaling on machine to set sensor. 112_Occurance_Before.png |
| Occurance (After) |
Scaling provided to set sensor. 112_Occurance_After.png |
| Outflow (Before) |
Process validation report. 112_Outflow_Before.jpg |
| Outflow (After) |
Air gauge to inspect 100% at inward inspection stage. 112_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Not applicable. |
12. Document Review
| Documents | PMCheckSheet, PokayokeCheckSheet, InspCheckSheet |
| Specify Other Document | Inward check sheet. |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | ok |