QFR No - 8000827660
Defect Details
| NC No. | 8000827660 |
| NC Date | 26/04/2023 |
| NC Submission Date | |
| Part No. | 5230103200 |
| Part Name | THROTTLE CONTROL PULLY FOR H BAR ASSLY |
| Supplier Name & Code | 101086-PUNE POLYMERS PVT. LTD. |
| ETL Plant | 1102-ETL L-6 Die Casting |
| Defect Details | FITTMENT NOT OK.-ID 21.95 UNDERSIZE |
1. Problem Description
| Defect Description | Fitment ID dia 21.95 undersize . Spec 21.95 observed 21.7. to 21.80 |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 42 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qa.waluj@punepolymers.com |
| Plant Head/CEO Email ID | planthead.waluj@punepolymers.com |
| MD Email ID | s.gupta@punepolymers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
3000
|
0
|
0
|
0
|
5000
|
8000
|
| Check Qty |
3000
|
0
|
0
|
0
|
5000
|
8000
|
| NG Qty |
0
|
0
|
0
|
0
|
300
|
300
|
| Scrap | 0 |
| Rework | 300 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % inspection with gauge & green marking for confirmation. |
3. Process Flow
| Process Flow Description |
|---|
| Receipt - Injection molding - Annealing - De-flashing -Inspection |
4. Process Details
| Process / Operation | Injection molding |
| Outsource | No |
| Machine / Cell | Injection mold shop |
| Machine / Cell No. | IM 100T |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Less dia of punch in mold | 22.04 mm against requirement of 22.20 mm | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | DVC |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10 Nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Fitment issue |
| Why 2 | ID undersize. |
| Why 3 | Punch dia less (22.04 mm) in the mold. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Punch dia less (22.04 mm) in the mold. |
Root Cause Analysis (Outflow)
| Why 1 | Fitment issue |
| Why 2 | ID undersize. |
| Why 3 | Not detected in sampling. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Not detected in sampling. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | New punch with increased dia of 22.20 mm replaced to meet ID dimensions as per specification 21.95 ± 0.1 mm. | Balu Kasbe | 25/05/2023 | Inprocess |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection by Plug gauge instead of DVC |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
10. Evidance of Countermeasure
| Occurance (Before) |
Punch dia less (22.04 mm) in the mold. 439_Occurance_Before.xlsx |
| Occurance (After) |
New punch with increased dia of 22.20 mm replaced to meet ID dimensions as per specification 21.95 ± 0.1 mm. 439_Occurance_After.xlsx |
| Outflow (Before) |
Not detected in sampling. 439_Outflow_Before.xlsx |
| Outflow (After) |
100 % inspection of part by QA inspector by "GO" "NOGO" plug gauge before thread weaving of part & green marking for confirmation. 439_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Throttle control pulley 24191101 |
12. Document Review
| Documents | PMCheckSheet, PFMEA, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |