QFR No - 8000822129
Defect Details
| NC No. | 8000822129 |
| NC Date | 28/02/2023 |
| NC Submission Date | |
| Part No. | 520FW04702 |
| Part Name | CLUTCH HOUSING FULL FINISHED-K70 |
| Supplier Name & Code | 100656-MADHURA DIE CAST PVT.LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | RUN OUT MORE-Ø36 MM OD R/O UPTO 0.58 MM AGAINST 0.04 |
1. Problem Description
| Defect Description | Customer Complaint -Clutch DFCE Oversize up to 0.55 mm due Housing Clutch OD Ø36 mm Run out found oversize up to 0.45~0.58 mm against 0.04 mm |
| Detection Stage | Customer End |
| Problem Severity | Fitment |
| NG Quantity | 4 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
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 |
500
|
0
|
0
|
600
|
800
|
1900
|
| Check Qty |
500
|
0
|
0
|
600
|
800
|
1900
|
| NG Qty |
1
|
0
|
0
|
1
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Inspection done at ETL End by dial and mandrel with blue dot marking on OD. |
3. Process Flow
| Process Flow Description |
|---|
| 1. Casting 2.fetling 3. CNC 1st Set-up 4. CNC 2nd Set-up 5.Final Inspection. |
4. Process Details
| Process / Operation | CNC 2nd Set-up |
| Outsource | No |
| Machine / Cell | CNC CELL |
| Machine / Cell No. | CNC N0.05 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled operator was operating machine | Level -04 operator is operate machine. | O |
| Material | Burr on clamping area | Verify the component found ok | O |
| Machine | Center bolt of Chuck was loose | H Sheet is verify but retightening point not updated in sheet. | X |
| Tool | component was not clamp properly in jaw | Jaw pressure found not ok running condition | X |
6. Inspection Method Analysis (Current)
| Inspection Method | 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 | Concentricity Of Outer Diameter 36.00 mm wrt ID 22.0 mm Found 0.4 mm against 0.02 mm. |
| Why 2 | n 2nd setup CNC machining Job gets loose in running. |
| Why 3 | Fixture locator boss was loose. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | In machine running condition, the center bolt in the chuck was gets loose. |
Root Cause Analysis (Outflow)
| Why 1 | Inspector checking method was sampling basis |
| Why 2 | gauging checking frequency was less |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | gauging checking frequency was less |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Additional tightening arrangement by Grub Screw provided for Centre bolt of locator boss to avoid the centre bolt loose issue | PRODUCTION supervisor | 10/03/2023 | 08/03/2023 | Completed |
| Outflow | Training and awareness given to inspector for checking 100% Concentricity Of Outer Diameter 36.00. wrt ID 22.0 With reading on job in micron. | QA Engineer | 10/03/2023 | 08/03/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Started 100% Concentricity Of Outer Diameter 36.00. wrt ID 22.0 With reading on job in micron |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
JH Sheet is not updated for Centre bolt retightening 381_Occurance_Before.pdf |
| Occurance (After) |
JH Sheet is updated for Centre bolt retightening frequency and method 381_Occurance_After.pdf |
| Outflow (Before) |
Runout checking frequency is sample basis. 381_Outflow_Before.pdf |
| Outflow (After) |
Runout checking frequency change sample to 100% and reading mentioned on part. 381_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Machine N0.01 |
12. Document Review
| Documents | ControlPlan, JHCheckSheet, InspCheckSheet |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 2000 |
| Reason for submission | OK |