QFR No - 8000808151
Defect Details
| NC No. | 8000808151 |
| NC Date | 17/10/2022 |
| NC Submission Date | |
| Part No. | S2BG03908B |
| Part Name | BKT POWDER COATED |
| Supplier Name & Code | 101032-ASM CASTINGS PRIVATE LIMITED ( |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | THREADING NOT OK-THREADING NOT OK |
1. Problem Description
| Defect Description | KHI Bracket observed with step at ID side concern. This causing assembly fitment (Rubber bush fitment) not OK. |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 553 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@asmcastings.in |
| Plant Head/CEO Email ID | skaul@asmcastings.in |
| MD Email ID | rajiv@asmcastings.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
1200
|
0
|
2800
|
0
|
6000
|
| Check Qty |
2000
|
1200
|
0
|
2800
|
0
|
6000
|
| NG Qty |
553
|
128
|
0
|
221
|
0
|
902
|
| Scrap | 902 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Segregation at customer as well as ASM End. |
3. Process Flow
| Process Flow Description |
|---|
| R.M. Receiving - Die Casting - Fattling - Bush Fitting Dia Reamer - Drilling & Tapping - Visual Inspection - PDI -Packing - Dispatch - Powder Coating at Tulza Ent. - Dispatch to ETL. |
4. Process Details
| Process / Operation | Powder Coating |
| Outsource | Yes |
| Machine / Cell | Die Casting |
| Machine / Cell No. | PDC-01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Hard Particle in Al Ingot. | Chemical Composition | O |
| Method | Reamer not adequate | Remer Size Checked | O |
| Man | Un Skilled Operator | Skill Matrix | O |
| Tool | Pin Bulged in Die | Physical Verification | X |
| Machine | Play in Machine Platon | Physical Verification | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 Nos. |
7. Root Cause Analysis (Occurance)
| Why 1 | Step Observed in ID |
| Why 2 | Pin Bulged during Mass Production |
| Why 3 | Not Checked in Process Inspection |
| Why 4 | Check Point not added in Inspection td. |
| Why 5 | |
| Root Cause (Occurance) | Check point not added in Inspection Std. for Step in I.D. |
Root Cause Analysis (Outflow)
| Why 1 | Step in I.D. |
| Why 2 | Could Not detected during Final Inspection |
| Why 3 | Inspector Not aware about Issue. |
| Why 4 | Check Point not added in Work Instruction. |
| Why 5 | |
| Root Cause (Outflow) | Check For Step in I.D. , not added in Work Instruction of Final Inspection. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Check Point added for Step In I.D. in Inspection Std. of PDC. | Lalit Sharma | 10/11/2022 | Completed | |
| Outflow | Check Point added in Work Instruction of Final Inspection | Lalit Sharma | 10/11/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Earlier Limit Sample was not there for Compare |
| Inspection Method | Other |
| Other Inspection Method | Limit Sample. |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
No Check Point at PDC stage for Step in I.D. 288_Occurance_Before.jpg |
| Occurance (After) |
Check Point added for step in ID at PDC Stage 288_Occurance_After.jpg |
| Outflow (Before) |
No Check Point for Step in I.D. in Work Instruction & No Limit Sample 288_Outflow_Before.jpg |
| Outflow (After) |
Check point added in Work Instruction at Final Stage & Limit Sample Provided. 288_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | PDC Machine |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | Limit Sample |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | No any reoccurance. |