QFR No - 8000803430
Defect Details
| NC No. | 8000803430 |
| NC Date | 08/09/2022 |
| NC Submission Date | |
| Part No. | 520FW04602 |
| Part Name | CLUTCH HOUSING FULL FINISHED |
| Supplier Name & Code | 100656-MADHURA DIE CAST PVT.LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | POROSITY-POROSITY OBSERVED LEVEL L5/L6 |
1. Problem Description
| Defect Description | POROSITY OBSERVED LEVEL L5/L6 |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 4 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | madhuradiecast@gmail.com |
| Plant Head/CEO Email ID | madhuradiecast@gmail.com |
| MD Email ID | madhuradiecast@gaikegroup.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
500
|
0
|
0
|
3500
|
500
|
4500
|
| Check Qty |
500
|
0
|
0
|
3500
|
500
|
4500
|
| NG Qty |
4
|
0
|
0
|
3500
|
500
|
4004
|
| Scrap | 4004 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Component are hold & rejected at our end. 4000 Nos rejected. |
3. Process Flow
| Process Flow Description |
|---|
| 1.Casting 2.fetling 3. CNC 1st Set-up 4.CNC 2nd Set-up 5.Final Inspection. |
4. Process Details
| Process / Operation | Casting |
| Outsource | No |
| Machine / Cell | HPDC |
| Machine / Cell No. | HPDC NO.04 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | 1.3W4S Housing MSI insert gate area got erosion. | We checked whether the die is erosion or not | X |
| Tool | Cooling system of die | Cooling system of die found ok condition | O |
| Tool | Venting system of die | Die loading and unloading inspection sheet checked found ok | O |
| Machine | Plunger velocity 1ST stage | Velocity of plunger checked as per process standard sheet found | O |
| Tool | Temperature of die | Temperature of die found as per process sheet | O |
| Machine | Plunger velocity is 2nd stage | Velocity of plunger checked as per process standard sheet found | O |
| Machine | Multi pressure 3rd stage | Multi stage pressure checked as per process standard sheet found | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | X- Ray test feq less |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | NA |
7. Root Cause Analysis (Occurance)
| Why 1 | 3W4S Housing MSI insert gate area got erosion. |
| Why 2 | Heat zone was created. |
| Why 3 | The heat zone created at the gate area thickness was low 73.25mm. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | The heat zone created at the gate area thickness was low 73.25mm. |
Root Cause Analysis (Outflow)
| Why 1 | X-ray testing frequency was less. |
| Why 2 | X-ray testing plan not available. |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | X-ray testing frequency was less. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 1. X-ray testing frequency changes once in a year to Quarterly. | QA Engineer | 01/10/2022 | 05/10/2022 | Completed |
| Occurance | 1.In 3W4S Housing MSI insert modified at gate area radius is R1 and R3. 2.Material gate area dimension modified up to 75.00mm. 3.Die inspection check sheet is implemented at loading and unloading on machine stage. | Production Supervisior PDC | 12/10/2022 | 14/10/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 1. X-ray testing frequency changes once in a year to Quarterly. |
| Inspection Method | Other |
| Other Inspection Method | X-ray Testing |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | NA |
10. Evidance of Countermeasure
| Occurance (Before) |
1..3W4S Housing MSI insert gate area got erosion.
2.Material entry gate area dimension found 73.25mm against 75.00mm. 249_Occurance_Before.png |
| Occurance (After) |
1.In 3W4S Housing MSI insert modified at gate area radius is R1 and R3 as shown by a green circle.
2.Material gate area dimension modified up to 75.00mm. 3.Porosity level on part found L1/L2 249_Occurance_After.png |
| Outflow (Before) |
X-ray testing frequency was less. 249_Outflow_Before.jpg |
| Outflow (After) |
X-ray testing frequency changes once in a year to Quarterly. 249_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | K70 Housing Clutch |
12. Document Review
| Documents | ControlPlan, PFMEA, AuditCheckSheet |
| Specify Other Document | Testing Plan |
13. Effectiveness Of Action
| Reviewed Quantity | 4000 |
| Reason for submission | 1)No recurrence of defect phenomenon, 2)X Ray Inspection frequency optimized from once in year to Quarterly |