QFR No - 8000789394
Defect Details
| NC No. | 8000789394 |
| NC Date | 30/05/2022 |
| NC Submission Date | |
| Part No. | S2BY03451B |
| Part Name | CANISTER SQR GROOVE LEAK TESTED |
| Supplier Name & Code | 100465-PN DIE CASTINGS PVT LTD |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | DIMN.O/SIZE.-GR0OVE WIDTH OVERSIZE |
1. Problem Description
| Defect Description | Groove Dim. 4.10+0.10 observed upto 4.32,4.40,4.45 and the Step height 2±0.10 just below the Groove observed as 1.64,1.53,1.62. and Dim. 1.50+0.10 observed as 1.24,1.36,1.31 |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1335 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualityqh@bansaldiecastings.com |
| Plant Head/CEO Email ID | gm@bansaldiecastings.com |
| MD Email ID | piyush@bansaldiecastings.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1500
|
0
|
0
|
3000
|
100
|
4600
|
| Check Qty |
1500
|
0
|
0
|
3000
|
100
|
4600
|
| NG Qty |
1500
|
0
|
0
|
3000
|
100
|
4600
|
| Scrap | 4600 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1.Segrigated all store ,wip & Assly area at customer end(1500 qty) by the leak testing machine and found All part not ok- Akshay 2.Segrigated all store & wip at BDC end(3100 qty) by the HG & VC 60 nos and 3040 nos by template ,found All part not ok- Bhuvan |
3. Process Flow
| Process Flow Description |
|---|
| 10.RM receiving & inspection 20.Die casting & inspection 30.Fettling & Filing 40.Shot blasting 50.Drilling 60.VMC machining......(Incident station) 70.Air cleaning 80.Impregnation 90.Pin Pressing 100.Leak Testing 110.Final inspection 120.Packing & storage 130.Dispatch |
4. Process Details
| Process / Operation | Machining/Grooving |
| Outsource | No |
| Machine / Cell | VMC09/Machining |
| Machine / Cell No. | VMC09/B03 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Groove tool not ok | Groove tool inspection not done | X |
| Machine | Vibration in machine, new machine, New Fixture | PM check sheet & 4M verified , Found ok | O |
| Material | Wrong grade | MTC & LTC verified , Found ok | O |
| Man | Untrained operator/ inspector | Skill matrix verified & found ok | O |
| Method | Groove inspection is not done during FPA | FPA report verified & found groove inspection point missing | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | First peace approval |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 0 |
7. Root Cause Analysis (Occurance)
| Why 1 | Leakage in Canister |
| Why 2 | Groove O Ring loose |
| Why 3 | Groove width over size |
| Why 4 | Groove tool not ok |
| Why 5 | |
| Root Cause (Occurance) | Groove tool not Ok |
Root Cause Analysis (Outflow)
| Why 1 | Leakage in Canister |
| Why 2 | Groove O Ring loose |
| Why 3 | Groove width over size |
| Why 4 | Groove width inspection Point miss in FPA report & PDI report |
| Why 5 | |
| Root Cause (Outflow) | Groove width inspection Point miss in FPA report |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1.Quality alert 2. Tool incoming inspection report 3.Set up approval report | Abhay saxena & Akshay | 02/06/2022 | 02/06/2022 | Completed |
| Outflow | 1.OPL 2.OJT 3.Point Add in FPA Report 4.Point add in PDI report | Akshay | 03/06/2022 | 03/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 1.1 no`s groove width inspection in every shift(During FPA) by VC in every shift after parting of sample part . 2. 1 no`s groove width inspection in every lot(During PDI) by VC in every lot after parting of sample part . |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 1 |
10. Evidance of Countermeasure
| Occurance (Before) |
No tool Inspection report 156_Occurance_Before.xlsx |
| Occurance (After) |
Tool inspection report available 156_Occurance_After.xlsx |
| Outflow (Before) |
Groove width inspection Point miss in FPA report & PDI report 156_Outflow_Before.xlsx |
| Outflow (After) |
Groove width inspection Point miss added in FPA report & PDI report 156_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | No |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, AuditCheckSheet, InspCheckSheet |
| Specify Other Document | FPA & PDI report |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | Found OK |