QFR No - 8000796864
Defect Details
| NC No. | 8000796864 |
| NC Date | 26/07/2022 |
| NC Submission Date | |
| Part No. | F800500507 |
| Part Name | UNDER BRACKET ASSEMBLY |
| Supplier Name & Code | 100060-A.G.TRANSMISSIONS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-BUSH WEDLING FAILURE |
1. Problem Description
| Defect Description | BUSH WELDING FAILURE IN UNDER BRACKET K1 |
| Detection Stage | Customer End |
| Problem Severity | Safety |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | ymoraskar@agtransmissionsindia.com |
| Plant Head/CEO Email ID | agforge@rediffmail.com |
| MD Email ID | agtransmissions@rediffmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
745
|
1050
|
0
|
450
|
0
|
2245
|
| Check Qty |
745
|
1050
|
0
|
450
|
0
|
2245
|
| NG Qty |
745
|
1050
|
0
|
450
|
0
|
2245
|
| Scrap | 2245 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| We have done 100% inspection at our end, by recalling suspected lot. Then 2245 Nos. shafts are done scrap. |
3. Process Flow
| Process Flow Description |
|---|
| Forging Incoming, Bracket Machining, Shaft Machining, Insert Pressing & welding, Shaft Machining, Assembly Welding, Powder Coating, Tapping, Fine Boring, Final Inspection |
4. Process Details
| Process / Operation | Insert Pressing & welding |
| Outsource | No |
| Machine / Cell | Welding Machine |
| Machine / Cell No. | WT-03 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Setting SOP not followed | SOP Followed | O |
| Machine | Current Voltage Setting | Current Voltage Setting found OK | O |
| Material | Shaft I. D. | Shaft I. D. found OK | O |
| Material | Shaft O. D. | Shaft O. D. | O |
| Machine | Poor Welding Penetration | Poor Welding Penetration found OK | O |
| Machine | Gas flow | Gas flow found OK | O |
| Machine | Gun angle | Gun angle found NOT OK | X |
| Machine | Gun position | Gun position found OK | O |
| Machine | Fixture Run out | Fixture Run out is more than spec | X |
| Material | Oil on welding area on shaft I.D. | No oil | O |
| Material | Oil on insert O.D | Found OK | O |
| Man | Unskilled Operator | Skilled Operator was present | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Insert came out breaking the welding rig |
| Why 2 | Welding was on face of insert |
| Why 3 | Fixture runout found 0.35 mm |
| Why 4 | The machine runout increase with regular use |
| Why 5 | Fixture runout not checked during first piece inspection |
| Root Cause (Occurance) | Fixture runout not checked during first piece inspection |
Root Cause Analysis (Outflow)
| Why 1 | Insert came out breaking the welding rig |
| Why 2 | Welding was on face of insert |
| Why 3 | Gun angle Out of Spec |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Gun angle Out of Spec |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Fixture is updated for having runout 0.2mm max. Fixture run out is checked in first piece and added in PM list | Production & Maintenance | 12/08/2022 | 12/08/2022 | Completed |
| Outflow | Welding gun holder modification for permanent setting and separate machine is allocated for Insert welding. Check point added in control plan & First piece inspection report. | Production Maintenance Quality | 12/08/2022 | 12/08/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | UTM Inspection frequency modified as First Sample, Middle Sample, Last Sample Per setting |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 3per setup |
10. Evidance of Countermeasure
| Occurance (Before) |
Welding Fixture runout not monitored 208_Occurance_Before.pdf |
| Occurance (After) |
Welding Fixture runout inspection frequency 1 per shift 208_Occurance_After.pdf |
| Outflow (Before) |
Gun Angle Old fixture, possibility of changes in Gun Angle 208_Outflow_Before.png |
| Outflow (After) |
Gun Angle NEW fixture lock Gun Angle 208_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Will prepare new Fixture for Gun angle for Assembly Welding |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, PokayokeCheckSheet, InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | Ok |