QFR No - 8000805167
Defect Details
| NC No. | 8000805167 |
| NC Date | 22/09/2022 |
| NC Submission Date | |
| Part No. | F1BF04233M |
| Part Name | OUTER TUBE M/C RH- K0LA DISC |
| Supplier Name & Code | 100017-DEKSON CASTINGS LIMITED. |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | BLOW HOLES-CASTING BLOW HOLES |
1. Problem Description
| Defect Description | blow holes |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 21 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | dr3tcca01njs00mekriaf3pk.pptx |
Supplier Communication Details
| Quality Head Email ID | quality@dekson.co.in |
| Plant Head/CEO Email ID | mr@dekson.co.in |
| MD Email ID | chetandekate@dekson.co.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
200
|
0
|
0
|
0
|
300
|
500
|
| Check Qty |
200
|
0
|
0
|
0
|
300
|
500
|
| NG Qty |
2
|
0
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All suspected part checked |
3. Process Flow
| Process Flow Description |
|---|
| Inward-Melting-Degassing-GDC-Riser Cutting-fettling grinding-GDC Q Gate- SPM-HT-VMC-BTA-Inspection- Dispatch |
4. Process Details
| Process / Operation | GDC |
| Outsource | No |
| Machine / Cell | GDC |
| Machine / Cell No. | 3 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Air vent block | found block | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
7. Root Cause Analysis (Occurance)
| Why 1 | CASTING BLOW HOLES |
| Why 2 | hot air gas not removed |
| Why 3 | Air vent block |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Air vent block |
Root Cause Analysis (Outflow)
| Why 1 | CASTING BLOW HOLES |
| Why 2 | blow hole open after buffing |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | blow hole open after buffing |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Air vent blockage clear | Die Maint. Operator | 24/09/2022 | 24/09/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | check point added in inspection checksheet |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 4 |
10. Evidance of Countermeasure
| Occurance (Before) |
Die air vent found block 260_Occurance_Before.jpg |
| Occurance (After) |
Die Air vent open 260_Occurance_After.jpg |
| Outflow (Before) |
No inspection checkpoint 260_Outflow_Before.jpeg |
| Outflow (After) |
inspection checkpoint added 260_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | all die |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | blow holes open after buffing at ETL Narasapura plant so need to improve in supplier end casting process |