QFR No - 8000820735
Defect Details
| NC No. | 8000820735 |
| NC Date | 16/02/2023 |
| NC Submission Date | |
| Part No. | 520FZ01902 |
| Part Name | HUB CLUTCH K70 |
| Supplier Name & Code | 100656-MADHURA DIE CAST PVT.LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | TAPPING O/SIZE.-CRACK & HEAVY TEPAR MACHINING |
1. Problem Description
| Defect Description | Tapper Machining (Dimn 28.2±0.1 mm found up to 27.89~28.48 mm) |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 2 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | oalbh4q0u5jzjx4ubsgt2ova.jpg |
Supplier Communication Details
| Quality Head Email ID | madhuradiecast@gmail.com |
| Plant Head/CEO Email ID | madhuradiecast@gmail.com |
| MD Email ID | madhuradiecast@gaikegroup.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
0
|
0
|
500
|
600
|
2100
|
| Check Qty |
1000
|
0
|
0
|
500
|
600
|
2100
|
| NG Qty |
2
|
0
|
0
|
1
|
1
|
4
|
| Scrap | 4 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1.100% All material segregation at customer end and inhouse end with identification blue marking. |
3. Process Flow
| Process Flow Description |
|---|
| 1.Casting 2.fetling 3. CNC 1st Set-up 4.CNC 2nd Set-up 5.Broaching 6.Final Inspection |
4. Process Details
| Process / Operation | CNC 2nd Set-up |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | 05 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Component was not rest proper in jaw | Check and verify possibility component rest inproper | X |
| Man | Unskilled operator was operate machine | Skill Matrix verify found Level-04 operator operate machine | X |
| Tool | Jaw loose in running | Check and verify found ok | O |
| Material | Burr and flash on resting face | Found ok | 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 | 1:25 |
7. Root Cause Analysis (Occurance)
| Why 1 | Tapper Machining (Dimn 28.2±0.1 mm found up to 27.89~28.48 mm) |
| Why 2 | In 2nd side machining Component was not properly resting in jaw. |
| Why 3 | While operator resting the component in the jaw not properly rest. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | While operator resting the component in the jaw not properly rest. |
Root Cause Analysis (Outflow)
| Why 1 | Inspection done by height gauge |
| Why 2 | Inspection frequency was less |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspection frequency was less |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Auto loader mechanism is implemented on 2nd side machining stage. | Production supervisior | 15/03/2023 | 28/02/2023 | Completed |
| Outflow | 1.Special dial gauge implemented for Taper machining checking 2.Training and awareness given to inspector for checking 100% Taper Machining Checking. | QA Supervisor | 15/03/2023 | 28/02/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Started 100% Checking on special dial gauge |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
Auto loader not available for component resting. 372_Occurance_Before.pdf |
| Occurance (After) |
Auto loader mechanism is implemented on 2nd side machining stage. 372_Occurance_After.pdf |
| Outflow (Before) |
Taper machining Dim checked by Height gauge 372_Outflow_Before.jpeg |
| Outflow (After) |
Taper machining Dim checked by Sp Dial gauge 372_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | PokayokeCheckSheet, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | OK -(Remark-Wrong Defect image upload -Wheel clutch photo upload instead of Hub clutch) |