QFR No - 8000805177
Defect Details
| NC No. | 8000805177 |
| NC Date | 22/09/2022 |
| NC Submission Date | |
| Part No. | F1BF04133M |
| Part Name | OUTER TUBE M/C LH- K0LA DISC |
| Supplier Name & Code | 100017-DEKSON CASTINGS LIMITED. |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | FITTMENT NOT OK.-BTA ID ISSUES |
1. Problem Description
| Defect Description | BTA ID ISSUE |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 94 |
| 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 |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| 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-BuffingFinal-Inspection- Dispatch |
4. Process Details
| Process / Operation | BTA |
| Outsource | No |
| Machine / Cell | BTA |
| Machine / Cell No. | 4 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | BTA Tool Wear out | Tool wear out before life end | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 2 per hour |
7. Root Cause Analysis (Occurance)
| Why 1 | FITTMENT NOT OK.-BTA ID ISSUES |
| Why 2 | BTA ID having minor line mark |
| Why 3 | Tool Wear out |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Tool Wear out |
Root Cause Analysis (Outflow)
| Why 1 | FITTMENT NOT OK.-BTA ID ISSUES |
| Why 2 | Part skipped from inspection |
| Why 3 | oversight by inspector |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | oversight by inspector |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Tool changed | Mr. Ingle | 30/09/2022 | 28/09/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
10. Evidance of Countermeasure
| Occurance (Before) |
Tool wear out 262_Occurance_Before.jpeg |
| Occurance (After) |
Tool life monitoring after tool changed 262_Occurance_After.jpeg |
| Outflow (Before) |
BTA line mark 262_Outflow_Before.jpg |
| Outflow (After) |
OPL Displayed 262_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All BTA |
12. Document Review
| Documents | AuditCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | reviewed 1000 number found ok |