QFR No - 8000798536
Defect Details
| NC No. | 8000798536 |
| NC Date | 04/08/2022 |
| NC Submission Date | |
| Part No. | 3630001833 |
| Part Name | M/C HANDLE BAR BODY 3W (24151274) BAJAJ |
| Supplier Name & Code | 100202-G P AUTO COMPONENTS |
| ETL Plant | 1102-ETL L-6 Die Casting |
| Defect Details | TAPPING O/SIZE.-M4 TAPPING OVERSIZE |
1. Problem Description
| Defect Description | Speedometer Cover M4 Tapping oversize |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 180 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@advantechgroup.co.in |
| Plant Head/CEO Email ID | advantechengg@rediffmail.com |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
3000
|
0
|
0
|
500
|
200
|
3700
|
| Check Qty |
3000
|
0
|
0
|
500
|
200
|
3700
|
| NG Qty |
180
|
0
|
0
|
0
|
0
|
180
|
| Scrap | 180 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% inspection done with Minor diameter pin |
3. Process Flow
| Process Flow Description |
|---|
| incoming inspection>OP-10( Face cut & ø 28 hole)>OP-20 ( 21.8Remer) > OP30 ( Speedometer drilling)>OP40( M4 Tapping)> OP50 ( Spot face Outside)> OP-60( Spot Face inside face)>OP70(10.5 reamer)> OP80 (Switch hole RH side drilling)> OP90 ( Switch hole LH side Drilling)> OP100( Switch Hole Tapping)> OP110( Final inspection) |
4. Process Details
| Process / Operation | OP30 ( Speedometer drilling) |
| Outsource | No |
| Machine / Cell | SPM-03 |
| Machine / Cell No. | SPM-03 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Wrong loading | OK | O |
| Man | New man Power | Skilled manpoer- Suirvanshi | O |
| Material | Wrong chemical composition | Chemsitry Found ok | O |
| Machine | Spindle run ok | Run out observed up to 8 micron | O |
| Tool | Drilling tapp damage | Drill tap found damage | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 part |
7. Root Cause Analysis (Occurance)
| Why 1 | m4 tapping over size( minor diameter not ok) |
| Why 2 | drill hole over size |
| Why 3 | ø3.6 drill burn out |
| Why 4 | unsufficient coolant flow |
| Why 5 | Coolant Flow nozzle jam. |
| Root Cause (Occurance) | Coolant Flow nozzle jam |
Root Cause Analysis (Outflow)
| Why 1 | m4 tapping over size( minor diameter not ok) |
| Why 2 | Part Not arrest on stage |
| Why 3 | inspection on sampling base at final inspection table only |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Minor diameter not check during inprocess, only doing at final inspection on sampling base |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Coolant flow nozzle change & checking frequency added in JH check sheet | Mr. Suryavanshi | 20/08/2022 | Pending |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | minor diameter inspection added in in process & 100% at final stage |
| 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) |
Coolant nozzle jam 223_Occurance_Before.png |
| Occurance (After) |
Coolant nozzle cleaned 223_Occurance_After.png |
| Outflow (Before) |
Core pin gauge check point not add in Inprocess inspection report 223_Outflow_Before.jpg |
| Outflow (After) |
Core pin gauge check point added in Inprocess inspection report 223_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Drilling SPM / Excellent Machine Tool / G P Auto |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |