QFR No - 8000825878
Defect Details
| NC No. | 8000825878 |
| NC Date | 10/04/2023 |
| NC Submission Date | |
| Part No. | B2HF03624O |
| Part Name | MCYL PISTON ANODISED-Ø12,K2 FRONT |
| Supplier Name & Code | 100505-A B AUTOCOMPONENTS |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | HIGHT O/SIZE.-EXCESS TIP AT TOP SIDE OF PISTON |
1. Problem Description
| Defect Description | Loose ring observed in part |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 4 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | headqaabauto@gmail.com |
| Plant Head/CEO Email ID | kamalabautocomponent@gmail.com |
| MD Email ID | abautocomponent@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
0
|
0
|
0
|
2000
|
3000
|
| Check Qty |
1000
|
0
|
0
|
0
|
2000
|
3000
|
| NG Qty |
4
|
0
|
0
|
0
|
0
|
4
|
| Scrap | 4 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Available 2000nos verified at AB. |
3. Process Flow
| Process Flow Description |
|---|
| RM - Turning - Tip grinding - Inspection - Anodizing - Final inspection - PDIR - Dispatch. |
4. Process Details
| Process / Operation | Turning |
| Outsource | No |
| Machine / Cell | Master Piston Cell |
| Machine / Cell No. | Master Piston Cell |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Nil | RM OK as per MTC | O |
| Man | No manual intervention in this problem | No manual intervention | O |
| Method | Yes | Some parts we are getting | X |
| Tool | Nil | Tool ok | O |
| Machine | Nil | Machine found ok as per check sheet. | 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 | Tip & Ring found in parts. |
| Why 2 | Generating in the process |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Process Problem |
Root Cause Analysis (Outflow)
| Why 1 | Tip & Ring found in parts. |
| Why 2 | Skipped from the inspection |
| Why 3 | New Inspector. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | New inspector. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 1. Awareness given to the inspectors at final inspection. 2. Defect photos available in defect matrix | Harshith | 22/04/2023 | 22/04/2023 | Completed |
| Occurance | 1. Process improvement taken place but still not controlled 100%, 2. Manual tip grinding doing. | Sudhir | 25/04/2023 | 25/04/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | Awareness given to inspectors. |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
|
| Occurance (After) |
|
| Outflow (Before) |
|
| Outflow (After) |
|
11. Horizontal Deployment
| Horizontal Deployment Required | |
| Applicable Machine / Model / Plant |
12. Document Review
| Documents | |
| Specify Other Document |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |