QFR No - 8000828138
Defect Details
| NC No. | 8000828138 |
| NC Date | 02/05/2023 |
| NC Submission Date | |
| Part No. | S2BG00702B |
| Part Name | BRACKET UN P/C |
| Supplier Name & Code | 100973-TESMO MOTORCAST PRIVATE LIMITE |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | CRACK-CRACK CASTING DEFECT |
1. Problem Description
| Defect Description | Bracket Broken due to cracked & casting defect |
| Detection Stage | Inprocess |
| Problem Severity | Safety |
| NG Quantity | 3 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | lmxzvtct5sbdx3tor2oddndi.jpg |
Supplier Communication Details
| Quality Head Email ID | rkhare@tesmomotorcast.com |
| Plant Head/CEO Email ID | harish.bala@tesmomotorcast.com |
| MD Email ID | svkallani@tesmomotorcast.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
3000
|
0
|
4320
|
2032
|
10500
|
19852
|
| Check Qty |
3000
|
0
|
0
|
2032
|
10500
|
15532
|
| NG Qty |
3
|
0
|
0
|
0
|
0
|
3
|
| Scrap | 3 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Check point added in final stage. |
3. Process Flow
| Process Flow Description |
|---|
| PDC - Reamer - Grinding - Buffing - Tapping - Packing |
4. Process Details
| Process / Operation | PDC |
| Outsource | No |
| Machine / Cell | PDC 350 Ton |
| Machine / Cell No. | PDC-5 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Part eject before core out | Part get tilted in hot condition and hair line crack generated at inner side | O |
| Tool | Core Slider get jam | Core not out completely before ejection operation | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Checking |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1 |
7. Root Cause Analysis (Occurance)
| Why 1 | HMCL Part cracked at its I-section |
| Why 2 | I-section area get weak due to hair crack generation |
| Why 3 | Part get tilted in hot condition while ejection process in PDC |
| Why 4 | Core not completely out and ejection done |
| Why 5 | Core slider Jam due to flash inside core sliding area |
| Root Cause (Occurance) | Machine run with flash in core area. |
Root Cause Analysis (Outflow)
| Why 1 | HMCL cracked part found at customer end |
| Why 2 | Crack not checked |
| Why 3 | Specified location crack checking not happening in final stage |
| Why 4 | Defect coming first time |
| Why 5 | |
| Root Cause (Outflow) | Point not available in check point of inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Tool to run with flash free | Sachin | 10/05/2023 | Pending | |
| Outflow | Crack check point added in inspection | Rahul Khare | 10/05/2023 | Pending |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Crack at I-section check point incorporated in final inspection |
| Inspection Method | Other |
| Other Inspection Method | Visual checking |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1 |
10. Evidance of Countermeasure
| Occurance (Before) |
CRACKED PART 444_Occurance_Before.jpg |
| Occurance (After) |
OK PART 444_Occurance_After.jpeg |
| Outflow (Before) |
CRACKED PART 444_Outflow_Before.jpg |
| Outflow (After) |
SAMPLE PLACED ON FINAL INSPECTION 444_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | KTEP |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | PART DISPLAY |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |