QFR No - 8000787544
Defect Details
| NC No. | 8000787544 |
| NC Date | 14/05/2022 |
| NC Submission Date | |
| Part No. | 520KS00102 |
| Part Name | RIVET BR 100 CLUTCH |
| Supplier Name & Code | 100049-METAFORGE ENGG.(I) PVT.LTD. |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | CRACK-HEAD CRACK |
1. Problem Description
| Defect Description | Head Crack |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 110 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qa@metaforgeindia.com |
| Plant Head/CEO Email ID | kaustubh@metaforgeindia.com |
| MD Email ID | prajakt@metaforgeindia.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
9000
|
0
|
0
|
0
|
0
|
9000
|
| Check Qty |
9000
|
0
|
0
|
0
|
0
|
9000
|
| NG Qty |
9000
|
0
|
0
|
0
|
0
|
9000
|
| Scrap | 0 |
| Rework | 9000 |
| Under Deviation | 0 |
| Containment Action |
|---|
| VIsual inspection- In sampling |
3. Process Flow
| Process Flow Description |
|---|
| Forging-Annealing- |
4. Process Details
| Process / Operation | Forging |
| Outsource | No |
| Machine / Cell | Forging |
| Machine / Cell No. | Forging |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Line marks on wire coil | Line mark shankand head | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | - |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
7. Root Cause Analysis (Occurance)
| Why 1 | Head found crack |
| Why 2 | During Head forging upsetting head found crack |
| Why 3 | Line mark on RM coil surface are on some portion |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Line mark on RM coil surface are on some portion |
Root Cause Analysis (Outflow)
| Why 1 | head found crack |
| Why 2 | Not detect in visual inspection |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Not detect in visual inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Not defined | Adarsh | 15/06/2022 | 20/07/2022 | Completed |
| Outflow | Vision base system ( proposal sent to ETL) | Adarsh | 15/06/2022 | 31/03/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | 0 |
| Inspection Method | Other |
| Other Inspection Method | - |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
10. Evidance of Countermeasure
| Occurance (Before) |
- 118_Occurance_Before.pdf |
| Occurance (After) |
- 118_Occurance_After.pdf |
| Outflow (Before) |
- 118_Outflow_Before.pdf |
| Outflow (After) |
- 118_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All rivet family |
12. Document Review
| Documents | |
| Specify Other Document | - |
13. Effectiveness Of Action
| Reviewed Quantity | 50000 |
| Reason for submission | 1.OK-No Repetition of Defect Phenomenon (Outflow side action OK) 2.Occurrence Side action to be submit |