QFR No - 8000832707
Defect Details
| NC No. | 8000832707 |
| NC Date | 13/06/2023 |
| NC Submission Date | |
| Part No. | 165FY01022 |
| Part Name | HUB CLUTCH BROACHED RE4S COMPACT+LPG |
| Supplier Name & Code | 100656-MADHURA DIE CAST PVT.LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | M/CING SHIFT.-TAPER MACHINING |
1. Problem Description
| Defect Description | Dimn 23.5±0.2 observed up to 23 mm (Tapper Machining) |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 7 |
| 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 |
1000
|
0
|
0
|
500
|
1000
|
2500
|
| Check Qty |
1000
|
0
|
0
|
500
|
1000
|
2500
|
| NG Qty |
7
|
0
|
0
|
0
|
0
|
7
|
| Scrap | 7 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Stock Segregation done at the Customer end, supplier end with blue dot marking |
3. Process Flow
| Process Flow Description |
|---|
| 1.Casting 2.fetling 3. CNC 1st Set-up 4.CNC 2nd Set-up 5.Broaching 6.Final Inspection |
4. Process Details
| Process / Operation | Casting |
| Outsource | No |
| Machine / Cell | HPDC |
| Machine / Cell No. | HPDC 400 TON |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Component was not clamp proper | Component resting position checked | O |
| Man | Low skill level operator deployed on Machine | Skill matrix chart checked found ok | O |
| Material | Burr on resting side of component | Component was verify burr found on resting area | X |
| Tool | Resting and clamping are not proper work | Pressure and resting position checked | O |
| Machine | Chuck pressure is low | Pressure checked found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 1:25 |
7. Root Cause Analysis (Occurance)
| Why 1 | Dim 24.30+/-0.15 observation 23.92 |
| Why 2 | Burr on was the component resting area. |
| Why 3 | Component was skipped from fettling operation |
| Why 4 | Machining done on was without fettling component. |
| Why 5 | |
| Root Cause (Occurance) | Machining done on was without fettling component. |
Root Cause Analysis (Outflow)
| Why 1 | Component was checking on Height gauge |
| Why 2 | Component checking on sampling basis |
| Why 3 | This dimension is checking in only in process stage in 2nd side operation |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | This dimension is checking in only in process stage in 2nd side operation |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1.Master sample Displayed at Fettling operation. 2.Work instruction of Fettling operation updated for burr is added & training given to fettling operator and inspector about defect. | PDC Supervisior | 24/06/2023 | 28/06/2023 | Completed |
| Outflow | 1.OPL Are displayed on Maching stage and final inspection table, 2.QA Alert Displayed. 3.Inspection frequency increased 1:25 to 1:10 and updated in control plan. | QA Engineeer | 24/06/2023 | 28/06/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection frequency increased 1:25 Nos to 1:10 Nos |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 1:25 |
10. Evidance of Countermeasure
| Occurance (Before) |
Master sample not displayed Work instruction not updated 477_Occurance_Before.jpg |
| Occurance (After) |
1.Master sample Displayed at Fettling operation. 2.Work instruction of Fettling operation updated for burr is added & training given to fettling operator and inspector about defect. 477_Occurance_After.pdf |
| Outflow (Before) |
Check point not added in final inspection stage. 477_Outflow_Before.png |
| Outflow (After) |
1.OPL Are displayed on Maching stage and final inspection table, 2.QA Alert Displayed. 3.Inspection frequency increased 1:25 to 1:10 and updated in control plan. 477_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | 1.HUB CLUTCH 3W4S MACHINED & BROACHED 2.HUB CLUTCH K70. |
12. Document Review
| Documents | ControlPlan, WISOP, InspCheckSheet |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 2000 |
| Reason for submission | OK |