QFR No - 8000801908
Defect Details
| NC No. | 8000801908 |
| NC Date | 27/08/2022 |
| NC Submission Date | |
| Part No. | F2FQ00507B |
| Part Name | HOLDER HANDLE P/C-XF-1C1 |
| Supplier Name & Code | 100001-ANANT ENTERPRISES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-CASTING DEFECTS |
1. Problem Description
| Defect Description | Handle Holder crack |
| Detection Stage | Customer End |
| Problem Severity | Safety |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | v31ykdfkq2upwkxneduumktr.pptx |
Supplier Communication Details
| Quality Head Email ID | anandkulkarni@anantgroup.co.in |
| Plant Head/CEO Email ID | pramodgosavi@anantgroup.co.in |
| MD Email ID | ashwinjoshi@anantgroup.co.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2112
|
3638
|
0
|
0
|
0
|
5750
|
| Check Qty |
2112
|
3638
|
0
|
0
|
0
|
5750
|
| NG Qty |
1
|
1
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Stock segregation done at ETL & Warehouse also Inspection marking implemented in half bore. |
3. Process Flow
| Process Flow Description |
|---|
| 10) RM receiving >>> 20) Storage>>> 30) Melting>>> 40) Degassing>>> 50) Casting>>>60) Cutting>>> 70)Grinding>>> 80) Heat treatment>>>90) Buffing>>>100) Powder coating>>>110) Machining>>> 120) Final inspection 130) Packaging & Forwarding |
4. Process Details
| Process / Operation | Casting |
| Outsource | No |
| Machine / Cell | 4 |
| Machine / Cell No. | 1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Molten metal pouring not OK | Pouring net not implemented during molten metal pouring, | X |
| Man | Operator skill | Semi skilled Operator - L2 | O |
| Material | Inclusion in metal | Metal cleaning frequency decided, Twice per lot. | O |
| Tool | Casting eject before solidification | Casting ejection done after solidification timer | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Impurity in Holder due to pouring net not using |
| Why 2 | Pouring net not using |
| Why 3 | Lack of awareness |
| Why 4 | Lack of training |
| Why 5 | |
| Root Cause (Occurance) | No awareness to use pouring net. |
Root Cause Analysis (Outflow)
| Why 1 | Holder Crack or broken due to strength reduced |
| Why 2 | Impurity in holder. |
| Why 3 | Impurity can not visualize at final inspection. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Impurity can not visualize at final inspection. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | WI modified to Use the Pouring net. | Kailas Adhave | 27/08/2022 | Pending | |
| Outflow | Inspection marking has been implemented in half bore. | Kailas Adhave | 26/08/2022 | Pending | |
| Outflow | OPL given to inspector & operator | Kailas Adhave | 26/08/2022 | Pending | |
| Occurance | Pouring net implement during metal pouring in die | Pramod Gosavi | 27/08/2022 | Pending | |
| Occurance | Q-Alert displayed at shop floor | Kailas Adhave | 27/08/2022 | Pending | |
| Occurance | Training has been give to die operator | Mahesh Punde | 27/08/2022 | Pending |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection identification implemented in half bore. |
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Without pouring net 232_Occurance_Before.bmp |
| Occurance (After) |
Pouring net Implemented 232_Occurance_After.bmp |
| Outflow (Before) |
Only DOT mark was implemented 232_Outflow_Before.jpg |
| Outflow (After) |
Inspection mark - Inspector initial implemented 232_Outflow_After.bmp |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Upper bracket |
12. Document Review
| Documents | ControlPlan, PFMEA, InspCheckSheet |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |