QFR No - 8000822018
Defect Details
| NC No. | 8000822018 |
| NC Date | 28/02/2023 |
| NC Submission Date | |
| Part No. | C2FY00233M |
| Part Name | HUB CL. WITH INSERT MACHINED-D1 |
| Supplier Name & Code | 100874-ANUSHRUSHTI AUTO PARTS |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | RUN OUT MORE-FACE R/O O/S UP TO 0.13 AGAINST 0.05 |
1. Problem Description
| Defect Description | D1 Hub Clutch run out found oversize up to 0.13 mm against 0.05 mm |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 11 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qlty@anushrushtiautoparts.com |
| Plant Head/CEO Email ID | anushrushti2011@rediffmail.com |
| MD Email ID | rrwable@redffmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
300
|
0
|
0
|
100
|
0
|
400
|
| Check Qty |
300
|
0
|
0
|
100
|
0
|
400
|
| NG Qty |
11
|
0
|
0
|
0
|
0
|
11
|
| Scrap | 11 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Part segregation done at ETL End |
3. Process Flow
| Process Flow Description |
|---|
| 1. casting inward 2. casting inward inspection 3.STORAGE 4.CNC 1st SETUP 5.CNC 2nd SETUP 6.DRILLING 7.FINAL INSPECTION 8.PACKING & STORAGE 9.PDI 10.DISPATCH & LOGISTICS |
4. Process Details
| Process / Operation | 1.CNC 1st SETUP 2.CNC 2nd SETUP 3.DRILLING |
| Outsource | No |
| Machine / Cell | CNC & DRILLING |
| Machine / Cell No. | CNC 1ST ,CNC 2ND |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | unskilled operator | skilled matrix verified found L1 | X |
| Material | Hub teeth inclined | Teeth inclination verified & found ok | O |
| Tool | insert wear out | Tool life monitoring verified found ok | O |
| Machine | jaw boaring not ok | jaw boaring runout 0.1 against 0.01 | X |
| Method | inspection frequency was inadequite | in final inspection part inspection was sampling basis found not evident | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 1 no`s/bin |
7. Root Cause Analysis (Occurance)
| Why 1 | RUN OUT MORE-FACE R/O O/S UP TO 0.13 AGAINST 0.05 |
| Why 2 | 2. Jaw Run out observed oversize up to 0.1mm against 0.01mm. |
| Why 3 | Jaw bo done by machine operator absence of machine supervisor. |
| Why 4 | shift was run in extra working day thatwhy line supersior was absent |
| Why 5 | |
| Root Cause (Occurance) | Jaw boring done by machine operator absence of machine supervisor. |
Root Cause Analysis (Outflow)
| Why 1 | The process part inspection at final insp is not effective |
| Why 2 | Inspection frequcey is less |
| Why 3 | inspection done at final inspection i.e - one`s in a bins |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | At final inspection station inspection frequency less |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Jaw boring done by machine operator absence of machine supervisor. | malhari pawar | 21/04/2023 | 10/05/2023 | Completed |
| Outflow | At final inspection station inspection frequency les | A.deshmukh | 22/05/2023 | 16/05/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | At final inspection station inspection frequency revised from one`s in a bins to 2 no`s from every bins |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 2 no`s/Bin |
10. Evidance of Countermeasure
| Occurance (Before) |
OPERATOR SKILL EVALUATION NOT DONE 382_Occurance_Before.xlsx |
| Occurance (After) |
FOR CNC MACHINING STAGE WISE SKILL MATRIX MADE 382_Occurance_After.xlsx |
| Outflow (Before) |
FINAL INSP INSPECTION FREQUENCY REVISED FROM 5 NO`S PER LOT TO 1 NO`S PER BINS 382_Outflow_Before.xlsx |
| Outflow (After) |
FINAL INSP INSPECTION FREQUENCY REVISED FROM 1 NO`S PER BINS TO 2 NO`S PER BINS 382_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NO |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | CONTROL PLAN |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Root Cause & Cause side action same -Need to review the action plan . |