QFR No - 8000805728
Defect Details
| NC No. | 8000805728 |
| NC Date | 26/09/2022 |
| NC Submission Date | |
| Part No. | 520AM01202 |
| Part Name | BALL RACE |
| Supplier Name & Code | 100264-SAI INDUSTRIES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-CORE DEPTH AND SURFACE HARDNESS NOT OK |
1. Problem Description
| Defect Description | Case depth and surface hardness found not ok |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 2060 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | info@sai-industries.com |
| Plant Head/CEO Email ID | info@sai-industries.com |
| MD Email ID | umesh.honap@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2060
|
0
|
0
|
0
|
0
|
2060
|
| Check Qty |
2060
|
0
|
0
|
0
|
0
|
2060
|
| NG Qty |
2060
|
0
|
0
|
0
|
0
|
2060
|
| Scrap | 2060 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Verified in ETL found 60 nos. crack during assly. in 1200 Nos. After received in Sai will be scraped. In Logistic and in house No finish stock verify for crack. Information has been given to heat treatment supplier for minimize case depth and core hardness. |
3. Process Flow
| Process Flow Description |
|---|
| R/M - Cutting - Drilling - CNC Turning - Heat Treatment-C`less Grinding-Track & I/D Finish-Final Inspection-Packing & Dispatch. |
4. Process Details
| Process / Operation | Heat Treatment |
| Outsource | Yes |
| Machine / Cell | Furnace |
| Machine / Cell No. | Furnace |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | - | - | X |
| Tool | - | - | X |
| Method | Carburising cycle time and quenching temperature excess than specification found. | Carburising cycle time and quenching temperature excess than specification found. | O |
| Material | - | - | X |
| Machine | - | - | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | One\Lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Ball Race crack during assly. " |
| Why 2 | In destructive testing case depth and core harness is above specification. |
| Why 3 | Case depth found 1.20 and core hardness found 57RC. |
| Why 4 | In heat treatment cycle not followed by supplier. |
| Why 5 | Carburizing cycle time and quenching temperature excess than specification observed. |
| Root Cause (Occurance) | Carburizing cycle time and quenching temperature excess than specification found. |
Root Cause Analysis (Outflow)
| Why 1 | Ball Race crack during assly. |
| Why 2 | In Final Inspection above defect not detect. |
| Why 3 | Due to destructive testing parts not verify before frequency. |
| Why 4 | Destructive testing frequency not adequate. Currently is once In Six Month. |
| Why 5 | |
| Root Cause (Outflow) | Destructive testing frequency not adequate. Currently is once In Six Month. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Revised heat tretament control plan for to minimize Carburizing cycle time and quenching low temperature implemented . Carburising cycle(soaking) time changed 70 to 60 Minutes.Quenching temperature changed 860 to 850°C.Trial conducted for one lot & supplied with green dot mark on o/d 48 as identification. | Supplier & Sai | 25/09/2022 | 26/09/2022 | Completed |
| Outflow | One piece test quarterly in NABL lab for Case depth & Core Hardness started. Corrected one lot 500 nos.supplied to ETL with green dot on o/d 48 as a indetification mark.NABL lab report submitted along with lot. | Sai | 26/09/2022 | 26/09/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | - |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | One\Lot |
10. Evidance of Countermeasure
| Occurance (Before) |
CHT Cycle
Carburizing cycle time - 70 Minutes.
Quenching teperature - 860°C 264_Occurance_Before.pdf |
| Occurance (After) |
CHT Cycle
Carburizing cycle time - 60 Minutes.
Quenching teperature - 850°C 264_Occurance_After.pdf |
| Outflow (Before) |
3 rd Party inspection Frequency 6 month 264_Outflow_Before.pdf |
| Outflow (After) |
3 rd Party inspection frequency 3 Month 264_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Ball Race Regular |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | - |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | ok |