QFR No - 8000832689
Defect Details
| NC No. | 8000832689 |
| NC Date | 12/06/2023 |
| NC Submission Date | |
| Part No. | 16JPP00117 |
| Part Name | WHEEL CLUTCH REML 6 PLATE / 7 PLATE |
| Supplier Name & Code | 101100-CAST 4 ALUMINIUM PVT LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | RUN OUT MORE-TEETH ID R/O OBS 1.0 MM |
1. Problem Description
| Defect Description | Tapper Machining -Teeth Runout found more than 1 mm against 0.2 |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 159 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | info@cast4aluminium.com |
| Plant Head/CEO Email ID | infor@cast4aluminium.com |
| MD Email ID | kiran@cast4aluminium.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
500
|
0
|
0
|
200
|
1300
|
2000
|
| Check Qty |
500
|
0
|
0
|
200
|
1300
|
2000
|
| NG Qty |
159
|
0
|
0
|
200
|
1300
|
1659
|
| Scrap | 1659 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Pipeline Material checked 100 % for defects & Material quarantined and Scrapped. |
3. Process Flow
| Process Flow Description |
|---|
| RM- Melting- PDC - Gate cutting / Fettling- Machining - Final inspection - FG- PDI - Dispatch |
4. Process Details
| Process / Operation | Machining |
| Outsource | No |
| Machine / Cell | CNC machining |
| Machine / Cell No. | CNC Machining |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Jaw observed cracked. | Jaw observed cracked. | O |
| Man | Part skipped from inspection As inspector is not aware of defect. | Part skipped from inspection As inspector is not aware of defect. | 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 | REML 6 plate wheel observed with taper machining |
| Why 2 | During Machining operation job get shifted from location. |
| Why 3 | Job is not get clamped properly in jaw. |
| Why 4 | Jaw observed cracked |
| Why 5 | |
| Root Cause (Occurance) | Jaw observed cracked |
Root Cause Analysis (Outflow)
| Why 1 | Jaw observed cracked |
| Why 2 | Inspector is not aware of defect |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspector is not aware of defect |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Jaw observed cracked | Datta | 10/06/2023 | Completed | |
| Outflow | Detection poka-yoke provided at drilling &Tapping stage ( Part located in ID & Three spline hole ). OPL is displayed 3) Knowledge & training is provided to inspectors. | Manoj C | 10/06/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No change , OPL is displayed & training provided 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) |
Jaw observed Crack 472_Occurance_Before.xlsx |
| Occurance (After) |
Replaced with New 472_Occurance_After.xlsx |
| Outflow (Before) |
Visual 472_Outflow_Before.xlsx |
| Outflow (After) |
Visual with Training provided to Inspector & OPL is displayed 472_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applied to other Machines & Components ( wheels) |
12. Document Review
| Documents | WISOP |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Ok |