QFR No - 8000811541
Defect Details
| NC No. | 8000811541 |
| NC Date | 21/11/2022 |
| NC Submission Date | |
| Part No. | B2BK04703O |
| Part Name | CALIPER BODY RAW-YAMAHA CBS |
| Supplier Name & Code | 100986-MAP ALLOYS |
| ETL Plant | 1159-ETL E-71 Disc Brakes |
| Defect Details | DENTS & DAMAGES-CASTING DEFECTS DENT & DAMAGE,BLOW HOLE |
1. Problem Description
| Defect Description | Damage |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 51 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | vinayak@mapalloys.com |
| Plant Head/CEO Email ID | milind@mapalloys.com |
| MD Email ID | mapalloys3@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
3185
|
0
|
0
|
0
|
0
|
3185
|
| Check Qty |
3185
|
0
|
0
|
0
|
0
|
3185
|
| NG Qty |
51
|
0
|
0
|
0
|
0
|
51
|
| Scrap | 51 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Segregation done and awareness training provided |
3. Process Flow
| Process Flow Description |
|---|
| RM inward-Incoming Inspection-Storage of RM- Melting -Metal treatment-DIE PREPARATION & DIE LOADING- .CASTING -RUNNER/RISER CUTTING - 90.FETTLING/Grinding-HEAT TREATMENT- Heat No.Punching & SHOT BLASTING -FINAL INSPECTION-PACKING -STORE & DISPATCH |
4. Process Details
| Process / Operation | 90-FETTLING/Grinding |
| Outsource | No |
| Machine / Cell | 05/02 |
| Machine / Cell No. | 05/02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Casting handling | Casting handling evaluate | O |
| Tool | High point on die | High point on die evaluate | X |
| Machine | Machine running condition | Machine running condition evaluate | O |
| Method | Casting Hanging on trolley | Casting hanging on trolley evaluate | O |
| Material | Chemical composition | Chemical composition verified | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Hard flash at parting line |
| Why 2 | Gap between both halves of die |
| Why 3 | High point on parting surface of die |
| Why 4 | Die blue matching frequency inadequate |
| Why 5 | |
| Root Cause (Occurance) | Die blue matching frequency inadequate |
Root Cause Analysis (Outflow)
| Why 1 | No awareness of concern person. |
| Why 2 | Limit sample not displayed and no awareness training. |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Limit sample not displayed and no awareness training. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Die blue matching frequency changed from 6 months to 4 months for high point removal from die surface | Mr.Anil Dhande | 15/03/2023 | 30/03/2023 | Completed |
| Outflow | Material handling awareness training and limit sample displayed. | R.Pandey | 15/03/2023 | 30/03/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% visual inspection with dot mark for 3 lots |
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Blue matching frequency inadequate 306_Occurance_Before.xlsx |
| Occurance (After) |
Die blue matching frequency changed from 6 months to 4 months for high point removal from die surface 306_Occurance_After.xlsx |
| Outflow (Before) |
No limit sample displayed and awareness training about material handling 306_Outflow_Before.xlsx |
| Outflow (After) |
Limit sample displayed and awareness training provided 306_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | GDC machine/Yamaha/2 |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 432 |
| Reason for submission | ok ensure |