QFR No - 8000794827
Defect Details
| NC No. | 8000794827 |
| NC Date | 11/07/2022 |
| NC Submission Date | |
| Part No. | F800506307 |
| Part Name | STEERING SHAFT WELD ASLY. P/C |
| Supplier Name & Code | 100066-MARATHWADA AUTO COMPO PVT. LTD |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | DIAMETER OVER SIZE-O D O/S LINGTH O/SIZE |
1. Problem Description
| Defect Description | Dia/Threading/Total Length Over size |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 98 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qaunderbkt@macpl.com |
| Plant Head/CEO Email ID | sdkulkarni@macpl.com |
| MD Email ID | ajit.macpl@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
300
|
0
|
0
|
100
|
100
|
500
|
| Check Qty |
300
|
0
|
0
|
100
|
100
|
500
|
| NG Qty |
98
|
0
|
0
|
0
|
0
|
98
|
| Scrap | 98 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| CHECK 100% JOB AT ETL & MACPL END |
3. Process Flow
| Process Flow Description |
|---|
| NC PARTS FOUND WHILE CNC TURNING.(TOTAL LENGTH FOUND ON HIGHER END) |
4. Process Details
| Process / Operation | CNC TURNING |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | CNC |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | TOTAL LENGTH GAUGE WEAR OUT | CMM (CMM REPORT FOUND GAUGE WEAROUT) | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | ST.SHAFT TOTAL LENGTH O/S AT ETL END |
| Why 2 | SKIF AT FINAL INSPECTION OR CAUGE CALIBRATION NOT DONE |
| Why 3 | FINAL INSPECTION MARKING AVAILABLE ON JOB BUT FOUND OVER SIZE AT CUSTOMER |
| Why 4 | TOTAL LENGTH GAUGE FOUND OVER SIZE AT CNC MACHINE . |
| Why 5 | |
| Root Cause (Occurance) | TOTAL LENGTH CHECKING GAUGE FOUND OVER SIZE |
Root Cause Analysis (Outflow)
| Why 1 | ST.SHAFT TOTAL LENGTH O/S AT ETL END |
| Why 2 | SKIF AT FINAL INSPECTION OR CAUGE CALIBRATION NOT DONE |
| Why 3 | FINAL INSPECTION MARKING AVAILABLE ON JOB BUT FOUND OVER SIZE AT CUSTOMER |
| Why 4 | TOTAL LENGTH GAUGE FOUND OVER SIZE ON FINAL INSPECTION |
| Why 5 | |
| Root Cause (Outflow) | TOTAL LENGTH GAUGE FOUND OVER SIZE ON FINAL INSPECTION |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | 1.)BEFORE START PRODUCTION WILL CHECK TOTAL LENGTH ON HEIGHT GAUGE.2) TOTAL LENGTH GAUGE CHECK ON CMM EVERY MONTH. |
| 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) |
CMM GAUGE NOT DONE 197_Occurance_Before.jpg |
| Occurance (After) |
GAUGE CORRECTION 197_Occurance_After.jpg |
| Outflow (Before) |
CMM GAUGE NOT DONE 197_Outflow_Before.jpg |
| Outflow (After) |
GAUGE CORRECTION 197_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | na |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | Issue Resolved |