QFR No - 8000807947
Defect Details
| NC No. | 8000807947 |
| NC Date | 17/10/2022 |
| NC Submission Date | |
| Part No. | S2BG02502B |
| Part Name | BRACKET UN P/C KTEP |
| Supplier Name & Code | 100973-TESMO MOTORCAST PRIVATE LIMITE |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | THREADING NOT OK-THREADING NOT OK |
1. Problem Description
| Defect Description | Bracket KTEP observed with threading not ok concern. In every month major qty. rejected for same. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 967 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | rkhare@tesmomotorcast.com |
| Plant Head/CEO Email ID | harish.bala@tesmomotorcast.com |
| MD Email ID | svkallani@tesmomotorcast.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
767
|
0
|
0
|
0
|
0
|
767
|
| Check Qty |
767
|
0
|
0
|
0
|
0
|
767
|
| NG Qty |
767
|
0
|
0
|
0
|
0
|
767
|
| Scrap | 500 |
| Rework | 100 |
| Under Deviation | 67 |
| Containment Action |
|---|
| core pin bend issuse |
3. Process Flow
| Process Flow Description |
|---|
| pdc , debering ,remer , vibro ,chamfer ,taping , air claning ,pack |
4. Process Details
| Process / Operation | pdc,debering ,remer ,vibro ,chamfer ,taping |
| Outsource | No |
| Machine / Cell | pdc |
| Machine / Cell No. | pdc 250 1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | core pin bend | Gauge | O |
| Material | core pin hardness not ok | hardness testing report check | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | every hrs |
7. Root Cause Analysis (Occurance)
| Why 1 | Tap not gone up to required depth |
| Why 2 | Tap jam while completing its cycle |
| Why 3 | Hole pin perpendicularity not ok |
| Why 4 | Die core pin bend |
| Why 5 | Pin hardness not as per requirement |
| Root Cause (Occurance) | Core pin hardness not freeze. |
Root Cause Analysis (Outflow)
| Why 1 | Tap not gone up to required depth |
| Why 2 | Tap jam while completing its cycle |
| Why 3 | Hole pin perpendicularity not ok |
| Why 4 | Die core pin perpendicularity not ok |
| Why 5 | Perpendicularity not check |
| Root Cause (Outflow) | Core pin Perpendicularity checking frequency not defined. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | hourly pin hole perpendicularity checking | Rahul | 06/07/2023 | 25/06/2023 | Completed |
| Occurance | Pin hardness freeze | Ravi | 10/07/2023 | 26/06/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Perpendicularity checking started on hourly check on PDC |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 1000 |
10. Evidance of Countermeasure
| Occurance (Before) |
Core pin bend 290_Occurance_Before.jpg |
| Occurance (After) |
Due to the pin bend, taping was not done untill the end. 290_Occurance_After.jpg |
| Outflow (Before) |
Guaege install 290_Outflow_Before.jpg |
| Outflow (After) |
Guaege checking strat 290_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Pdc 250 t 1 KTEP Bracket |
12. Document Review
| Documents | JHCheckSheet, InspCheckSheet |
| Specify Other Document | Pm check sheet, Ins |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |