QFR No - 8000797659
Defect Details
| NC No. | 8000797659 |
| NC Date | 29/07/2022 |
| NC Submission Date | |
| Part No. | 520BZ00102 |
| Part Name | CAP OIL LOCK-LML |
| Supplier Name & Code | 100503-DIVYA INDUSTRIES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-STEP MARK & ID UNDERSIZE |
1. Problem Description
| Defect Description | STEP IN BACK FACE & ID 14MM UNDERSIZED BY 0.5MM |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 351 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@mahavirind.co.in |
| Plant Head/CEO Email ID | production@mahavirind.co.in |
| MD Email ID | rajesh@mahavirind.co.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2106
|
0
|
0
|
702
|
0
|
2808
|
| Check Qty |
2106
|
0
|
0
|
702
|
0
|
2808
|
| NG Qty |
351
|
0
|
0
|
13
|
0
|
364
|
| Scrap | 62 |
| Rework | 302 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Material Segregation at Customer End |
3. Process Flow
| Process Flow Description |
|---|
| 1)RM Inward- 2)store - 3)Traub facing/Main Bore Drilling 14.02/14.14/8.5Drill F8.5/ID Chamfer/OD Chamfer - 4)Bottom Chamfer.5)OD Grinding.6) Plating .7) Final Inspection .8) Dispatch |
4. Process Details
| Process / Operation | 3)Traub facing/Main Bore Drilling 14.02/14.14/8.5D |
| Outsource | Yes |
| Machine / Cell | Traub Section |
| Machine / Cell No. | Traub No.2( A-25) |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | ID boring on traub Machine | During ID boring 14.02 Drill edges Line Marks Observed | 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 | .. |
7. Root Cause Analysis (Occurance)
| Why 1 | Line Marks at the ID of 14.02 Main Bore |
| Why 2 | Main ID boring operation on Traub machine |
| Why 3 | 14.02 drill edges heavy Burr Sticked |
| Why 4 | Drill Edges Fraction In at Part ID |
| Why 5 | |
| Root Cause (Occurance) | Main Boring ID operation Process by wrong Method Machining |
Root Cause Analysis (Outflow)
| Why 1 | Line Marks at the ID of 14.02 Main Bore |
| Why 2 | Not Defect In Final Inspection |
| Why 3 | Final Inspector Not aware about lD Line Marks |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Final Inspector Not aware about lD Line Marks |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | ID Boring Process change Traub Machining To CNC Machining | Mr. Suresh Kapgate | 12/08/2022 | 12/08/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Visual Inspection Instead Of 20Nos Samples |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | .... |
10. Evidance of Countermeasure
| Occurance (Before) |
Main boring Operation On Traub Machine 214_Occurance_Before.xlsx |
| Occurance (After) |
Main Boring Operation Start on CNC machine 214_Occurance_After.xlsx |
| Outflow (Before) |
Sampling Basis Visual Inspection 20nos Per Bin 214_Outflow_Before.docx |
| Outflow (After) |
Main Bore ID 100% Visual inspection at Final Inspection stage. 214_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Cap Oil Locks |
12. Document Review
| Documents | ControlPlan, PFMEA, ProcessFlowChart |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |