QFR No - 8000804715
Defect Details
| NC No. | 8000804715 |
| NC Date | 19/09/2022 |
| NC Submission Date | |
| Part No. | 165FG01101 |
| Part Name | GEAR PRIMARY ASSLY 3W-4S 200 cc LPG |
| Supplier Name & Code | 100237-SANJEEV AUTO PARTS MRFS PVT LT |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | DIAMETER OVER SIZE-DIA 35.5-0.009/-0.034 OVER SIZE |
1. Problem Description
| Defect Description | DIAMETER FOUND OVER SIZE (DIM 35.5-0.009/-0.034 FOUND UPTO 35.550~35.70 MM) |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 36 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | vpwankhade@sanjeevgroup.com |
| Plant Head/CEO Email ID | rmtiwari@sanjeevgroup.com |
| MD Email ID | maithilee@sanjeevgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
500
|
0
|
0
|
0
|
0
|
500
|
| Check Qty |
500
|
0
|
0
|
0
|
0
|
500
|
| NG Qty |
10
|
0
|
0
|
0
|
0
|
10
|
| Scrap | 0 |
| Rework | 10 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregated All parts at ETL end. |
3. Process Flow
| Process Flow Description |
|---|
| RM Inward-bar cutting-billet cutting-hot forging-normalizing-shotblasting-coining-preturning-peircing-1peircing-2shaving-1-shaving-2milling-1-milling-2-finish turning 1st setup-finish turning-2set up-deburring--final inspection CNC blanks-Inward inspection cnc blank-tracibility marking-hobbing-teeth chamfering-gear shaving-heat treatment-shotblasting-id turning-bush pressing-bush turning-washing-Final Inspection |
4. Process Details
| Process / Operation | Hard Turning |
| Outsource | No |
| Machine / Cell | CNC Jobber 03 |
| Machine / Cell No. | CNC Jobber 03 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Tool Worn Out | Insert Worn out as it is Hard Turning Process, Tool Wear Pattern Is High. | 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 | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Why OD Oversize In Part |
| Why 2 | less Material got Removed From Part than expected in process |
| Why 3 | Insert Worn out |
| Why 4 | Insert Life was less than expected |
| Why 5 | |
| Root Cause (Occurance) | Insert Life was less that expected |
Root Cause Analysis (Outflow)
| Why 1 | Why Defectives Skipped From Inspection |
| Why 2 | Material Mixed Up |
| Why 3 | New Manpower deployed |
| Why 4 | Manpower needs training on Rejection Handling |
| Why 5 | |
| Root Cause (Outflow) | New Manpower, needs training on Rejection Handling |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Tool Life monitoring started, Tool Verification by Supervisor Started | Sandip Lahane | 02/10/2022 | 02/10/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % Inspection On Air Gauge with Paint Marking for Confirmation. |
| 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) |
No Tool Life Monitoring 256_Occurance_Before.xlsx |
| Occurance (After) |
Tool Life Monitoring Started 256_Occurance_After.xlsx |
| Outflow (Before) |
No Tool Inspection Point In Hourly Inspection Report 256_Outflow_Before.xlsx |
| Outflow (After) |
HIPR Updated 256_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Machine, ALL GPH Parts |
12. Document Review
| Documents | ControlPlan, WISOP, InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | POKA-YOKE to be implement at process side (Air Gauge inspection interlocked with Machine cycle) |