QFR No - 8000802986
Defect Details
| NC No. | 8000802986 |
| NC Date | 06/09/2022 |
| NC Submission Date | |
| Part No. | 520FG07802 |
| Part Name | GEAR PRIMARY DRIVEN (JZ) |
| Supplier Name & Code | 200172-AURANGABAD AUTO ENGG PVT LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | PCD SHIFT-SPRING SPOKET& 3BOSS PCD NOT OK |
1. Problem Description
| Defect Description | Spring Pocket PCD & Concentricity not OK |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 94 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | verma.aaepl@gmail.com |
| Plant Head/CEO Email ID | aaepl.pantnagar@sangkaj.com |
| MD Email ID | steel@sangkaj.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2150
|
0
|
0
|
2588
|
3500
|
8238
|
| Check Qty |
1150
|
0
|
0
|
2588
|
3500
|
7238
|
| NG Qty |
2
|
0
|
0
|
0
|
16
|
18
|
| Scrap | 0 |
| Rework | 16 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % WIP And Customer end all part rechecked by PCD relation gauge |
3. Process Flow
| Process Flow Description |
|---|
| Forging -CNC 1at setup - CNC 2nd Setup -Trimming - Kidney pocket deburring - CNC 1st setup - CNC 2nd Setup - Inspection -Hobbing -HT-ID Honning -Teeth Honning -Final Inspection - Dispatch |
4. Process Details
| Process / Operation | Trimming |
| Outsource | Yes |
| Machine / Cell | Trimming Press Machine |
| Machine / Cell No. | CNC Cell |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Jaw boring not done as per frequency | Jaw boring frequency not follow | O |
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/Per lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Part not answering to relation gauge |
| Why 2 | Window location shifted |
| Why 3 | Jaw boring out |
| Why 4 | Jaw boring not done as per frequency |
| Why 5 | |
| Root Cause (Occurance) | Jaw boring frequency not follow as control plan |
Root Cause Analysis (Outflow)
| Why 1 | Sampling inspection done at final stage |
| Why 2 | Inspection done as per control plan |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Sampling inspection done at final inspection stage |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Jaw boring cycle interlocked | Production In charge | 16/12/2022 | 15/12/2022 | Completed |
| Outflow | 100% inspection started | final inspector | 20/12/2022 | 12/12/2022 | Completed |
| Occurance | 100% inspection started at final inspection stage by relation gauge | Final Inspector | 01/12/2022 | 09/12/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Before we have checked on sampling basis after Complaint received we have started 100% inspection . |
| 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) |
Jaw boring not done as per frequency 247_Occurance_Before.xlsx |
| Occurance (After) |
Interlock implemented for jaw boring frequency monitoring 247_Occurance_After.xlsx |
| Outflow (Before) |
Sampling Inspection at final stage 247_Outflow_Before.xlsx |
| Outflow (After) |
100% Inspection done at final inspection stage 247_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | DX101004 - Gear Primary Driven |
12. Document Review
| Documents | ControlPlan, JHCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 3000 |
| Reason for submission | OK |