QFR No - 8000807148
Defect Details
| NC No. | 8000807148 |
| NC Date | 08/10/2022 |
| NC Submission Date | |
| Part No. | B35206400O |
| Part Name | BRAKE SHOE ASSLY ASK (ASF4) - EMARKING |
| Supplier Name & Code | 100822-ASK AUTOMOTIVE PVT. LTD. ( UNI |
| ETL Plant | 1159-ETL E-71 Disc Brakes |
| Defect Details | RUNOUT-PERPENDICUALIRITY NOT OK |
1. Problem Description
| Defect Description | Brake shoe rejected for tapper and run out issue |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 50 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | 52yu4gaq5goz4pel54r2ct1q.msg |
Supplier Communication Details
| Quality Head Email ID | bms@askbrake.com |
| Plant Head/CEO Email ID | am@askbrake.com |
| MD Email ID | pr@askbrake.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
4000
|
0
|
0
|
4000
|
2413
|
10413
|
| Check Qty |
4000
|
0
|
0
|
4000
|
2413
|
10413
|
| NG Qty |
50
|
0
|
0
|
0
|
0
|
50
|
| Scrap | 50 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material laying at ETL & ASK segregated 100%. |
3. Process Flow
| Process Flow Description |
|---|
| Receiving- Machining- Adhesive Application- Clamping - OD Grinding - Final Inspection & Packing |
4. Process Details
| Process / Operation | Brake Shoe |
| Outsource | No |
| Machine / Cell | OD Grinding Machine |
| Machine / Cell No. | 1202158 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Inspection Frequency | Inproces Inspection frequency of OD grinding is sufficient | O |
| Method | Sample Size | Sample inspection size of OD grinding need to improve | X |
| Method | OD grinding process | OD grinding process is automated. | X |
| Man | New Manpower | No new manpower appointed on OD grinding process | X |
| Man | Manpower Skill Level | All manpower have skill level III | X |
| Machine | Wheel dressing frequency | Once in a day, which needs improve | O |
| Material | Material changed | No change in material | 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 | 1set / hr |
7. Root Cause Analysis (Occurance)
| Why 1 | Runout observed more |
| Why 2 | In second shift found some parts out of specification during inspection |
| Why 3 | Wheel dressing frequency less. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Verified the process with every 50th set after setup and observed that in first shift no NG parts found and in mid of second shift we have found 1 or 2 sets NG for runout. Again we have done setup after wheel dressing and no runout observed in the part. |
Root Cause Analysis (Outflow)
| Why 1 | Runout observed more |
| Why 2 | Problem not captured during sampling inspection |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Problem not captured during sampling inspection. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1. Wheel dressing frequency increased from once in a day to once in shift. 2. Training given to process engineers and also associates to dress the grinding wheel once in a shift. | Prashant | 12/10/2023 | 12/10/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No Change |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 2 set / hr |
10. Evidance of Countermeasure
| Occurance (Before) |
Work Instruction Before 272_Occurance_Before.pdf |
| Occurance (After) |
Work Instruction 272_Occurance_After.pdf |
| Outflow (Before) |
Setup & IIR Before 272_Outflow_Before.pdf |
| Outflow (After) |
Setup & IIR 272_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All machines |
12. Document Review
| Documents | WISOP, InspCheckSheet |
| Specify Other Document | Setup & IIR |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |