QFR No - 8000832953
Defect Details
| NC No. | 8000832953 |
| NC Date | 15/06/2023 |
| NC Submission Date | |
| Part No. | 520AE01502 |
| Part Name | CORE PLATE LML |
| Supplier Name & Code | 100959-AAR CEE ENGINEERING WORKS UNIT |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | DAMAGES-CLAW WIDTH 15.+/-0.05 O/S 16.24 & DAMAGE |
1. Problem Description
| Defect Description | LML Core Plate damage at claw & Width gets oversize upto 16.24 mm against 15.8±0.05 mm (Fitment issue ) |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 2 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | afg4miylhknnpxt5w1xiz25m.jpg |
Supplier Communication Details
| Quality Head Email ID | qc@aarceeengg.com |
| Plant Head/CEO Email ID | qc@aarceeengg.com |
| MD Email ID | vaibhav.arora@aarceeengg.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
10000
|
25000
|
15000
|
10000
|
0
|
60000
|
| Check Qty |
10000
|
25000
|
15000
|
10000
|
0
|
60000
|
| NG Qty |
10
|
0
|
0
|
0
|
0
|
10
|
| Scrap | 10 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material hold and segregated with marking |
3. Process Flow
| Process Flow Description |
|---|
| RM receive +RM Store+ Holding cum molting +HPDC+Trimming Ist+Trimming 2nd +shot blasting +Stress reliving + Final inspection+ Sound test |
4. Process Details
| Process / Operation | trimming |
| Outsource | No |
| Machine / Cell | power press |
| Machine / Cell No. | 30 ton |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Improper tool setting | Observed setting done properly by tool setter(WI/PRM/002) F31/QAD(HIR-TRIM) | O |
| Method | improper checking method | checkd by vernier caliper during set-up & in-process inspection , But possibility is there to bypass | X |
| Method | part stuck in trimming tool | Observed part no chance of stucking in tool(WI/PRM/002) | O |
| Machine | Trimming tool blunt | Checked reshaping frequency proper adhered found ok | O |
| Machine | Insufficient air pressure | Observed pressure was 4 kg/cm2 found ok (WI/PRM/002) | O |
| Method | Improper method used for part remove from machine | Part not proper remove from back side ,chance of width over | X |
| Machine | Trimming machine not working properly | As per machine check sheet 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 | 5 pcs /2hr |
7. Root Cause Analysis (Occurance)
| Why 1 | Trimming part stucked in tool ,chance of claw width over |
| Why 2 | Sometime parts get stuck up in Die after trimming and does not fly even puff of air. Operator keep running the machine continue, then core plate lug pressed by punch and claw width size become over. |
| Why 3 | There is narrow space for the trimming tool to come off when the part is stuck |
| Why 4 | No provision in tool to avoid such type issue |
| Why 5 | Claw width oversize possibility not considered as an failure mode in PFMEA during trimming |
| Root Cause (Occurance) | Claw width oversize possibility not considered as an failure mode in PFMEA during trimming |
Root Cause Analysis (Outflow)
| Why 1 | Checking method not sufficient to detect claw width over size on one claw at trimming & PDI |
| Why 2 | Claw width checked by vernier caliper ,during set-up, houlry & PDI, which does not ensure of whole lot /parts |
| Why 3 | Claw width oversized (One claw) possibility not considered while defined in control plan |
| Why 4 | No criteria for defining the inspection method in control plan |
| Why 5 | Procedure not available for control plan & inspection standard |
| Root Cause (Outflow) | Procedure not available for control plan & inspection standard |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Part ejection system to be made in trimming tool to avoid stuck issue | Radhesyam | 02/11/2023 | 02/11/2023 | Completed |
| Outflow | Control Plan to be updated- | Ajay Malik | 02/11/2023 | 02/11/2023 | Completed |
| Occurance | PFMEA updated for claw width oversize at one claw | Ajay Malik | 02/11/2023 | 02/11/2023 | Completed |
| Outflow | Inspection method improved | Ajay Malik | 02/11/2023 | 02/11/2023 | Completed |
| Outflow | Poison test to be done to verify the effectiveness of inspection- | Ajay Malik | 02/11/2023 | 02/11/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NO CHANGE |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 20 nos/hr |
10. Evidance of Countermeasure
| Occurance (Before) |
NO TRAINING RECORD 479_Occurance_Before.jpg |
| Occurance (After) |
TRAINING GIVEN TO THE OPERATOR 479_Occurance_After.pdf |
| Outflow (Before) |
Inspection method poor 479_Outflow_Before.pdf |
| Outflow (After) |
Indexing gauge implemented 479_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NO CHANGE |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 10000 |
| Reason for submission | Root Cause analysis not co-relate to defect phenomenon -Possibility of Core plate press during trimming operation |