QFR No - 8000807048
Defect Details
| NC No. | 8000807048 |
| NC Date | 08/10/2022 |
| NC Submission Date | |
| Part No. | B2GQ01003O |
| Part Name | MASTER CYLINDER BODY PDC RAW-K11,K2 |
| Supplier Name & Code | 100471-CASTALL TECHNOLOGIES (P) LTD |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | DIMENSSIONAL DEFECT-SLOT WIDTH O/S BY 0.2 MM |
1. Problem Description
| Defect Description | SLOT WIDTH O/S BY 0.2 MM |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qa@castalltech.com |
| Plant Head/CEO Email ID | sg@castalltech.com |
| MD Email ID | nmv@castalltech.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
0
|
0
|
0
|
1050
|
0
|
1050
|
| Check Qty |
0
|
0
|
0
|
1050
|
0
|
1050
|
| NG Qty |
0
|
0
|
0
|
1
|
0
|
1
|
| Scrap | 0 |
| Rework | 1 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% checked at vendors site |
3. Process Flow
| Process Flow Description |
|---|
| Operation # 50 |
4. Process Details
| Process / Operation | PDC |
| Outsource | No |
| Machine / Cell | PDC 400 |
| Machine / Cell No. | PDC 5 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | part mix up , slippage of gauge checking | verified | 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 | Excess fettling |
| Why 2 | gauge not checked after fettling |
| Why 3 | operators awareness |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Gauging after fettling to be assured by training and awareness program for the fettling team |
Root Cause Analysis (Outflow)
| Why 1 | Part mixed up in final inspection |
| Why 2 | No partition in final inspection table for "to be inspected " and "Inspected OK " area |
| Why 3 | No visual aid and no identification mark after gauge checking |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Partition implemented in Final Inspection area. Visual aid provided, parts identified with mark after 100% gauge checking |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Partition implemented for "To be Inspected" and "Inspected OK " parts | QA | 09/08/2022 | 23/08/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Change implemented with on job training of the inspector |
| 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) |
part mixed up 281_Occurance_Before.jpeg |
| Occurance (After) |
Partition provided 281_Occurance_After.jpeg |
| Outflow (Before) |
Without identification 281_Outflow_Before.jpeg |
| Outflow (After) |
100% gauge checking with identification, Visual aid provided 281_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Master cylinders variants |
12. Document Review
| Documents | WISOP |
| Specify Other Document | Visual aid |
13. Effectiveness Of Action
| Reviewed Quantity | 200 |
| Reason for submission | No Same defective parts found in received last lot |