QFR No - 8000808405
Defect Details
| NC No. | 8000808405 |
| NC Date | 19/10/2022 |
| NC Submission Date | |
| Part No. | F2BF26773B |
| Part Name | K0NA CBS OUTER TUBE CAST RH |
| Supplier Name & Code | 101262-SUNBEAM LIGHTWEIGHTING SOLUTIO |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | CENTRE DIST. NOT OK.-AXEL HOLE SHIFT |
1. Problem Description
| Defect Description | Wall thickness variation concern reported with major rejection qty. |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 269 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | deepak.rana@sunbeamauto.com |
| Plant Head/CEO Email ID | anoop.gupta@sunbeamauto.com |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
715
|
478
|
0
|
876
|
521
|
2590
|
| Check Qty |
715
|
478
|
0
|
870
|
521
|
2584
|
| NG Qty |
0
|
0
|
0
|
6
|
0
|
6
|
| Scrap | 6 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| casting should be catch on FI stage (oil seal coller wall 100% checked by vernier) |
3. Process Flow
| Process Flow Description |
|---|
| "1.Alloy Preparation 2.Degassing & Defluxing 3.Casting 4.Riser Cutting 5.Fettling & Filing 6.Leak Testing 7.Final Inspection " "1.Alloy Preparation 2.Degassing & Defluxing 3.Casting 4.Riser Cutting 5.Fettling & Filing 6.Leak Testing 7.Final Inspection " 1.alloy preparation 2.degassing and defuxing 3.casting 4.riser cutting 5.fettling and filling 6.leak testing 7.final inspection |
4. Process Details
| Process / Operation | casting |
| Outsource | No |
| Machine / Cell | gdc/domestic |
| Machine / Cell No. | 6 and 8 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | hydraulic pressure low | found pressure low | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Sp. 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 | Flash observed at parting line area |
| Why 2 | Die was not closing |
| Why 3 | Hydrulic pressure low |
| Why 4 | Cylinder leakage due to core holder was shaking . |
| Why 5 | Core holder change frequency was not deciding in pm plan cheek sheet . |
| Root Cause (Occurance) | Core holder change frequency was not deciding in pm plan cheek sheet . |
Root Cause Analysis (Outflow)
| Why 1 | Oil Seal area wall thickness ng |
| Why 2 | Process and final inspector in this problem not captured. |
| Why 3 | No check point avaiable in set up sheet and final work instruction sheet . |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No check point available in set up sheet and final work instruction sheet . |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Holder change frequency decided as per PM check sheet | kishore/mukesh | 05/11/2022 | Completed | |
| Outflow | check point add in process quality & final inspection | kishore/mukesh | 21/10/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% part inspection before dispatch |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Earlier core holder frequency not defined 292_Occurance_Before.pdf |
| Occurance (After) |
Holder change frequency decided as per PM check sheet 292_Occurance_After.pdf |
| Outflow (Before) |
No check point avaiable in set up sheet and final work instruction sheet . 292_Outflow_Before.pdf |
| Outflow (After) |
check point add in process quality & final inspection 292_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | 08/kona/101262 |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, WISOP, InspCheckSheet |
| Specify Other Document | na |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | No any re-occurance. |