QFR No - 8000833697
Defect Details
| NC No. | 8000833697 |
| NC Date | 21/06/2023 |
| NC Submission Date | |
| Part No. | 520FZ01902 |
| Part Name | HUB CLUTCH K70 |
| Supplier Name & Code | 100656-MADHURA DIE CAST PVT.LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | EXCESS M/CING-DIMN 21.20-0.25 OBS 20.73~2095 MM |
1. Problem Description
| Defect Description | Tapper Machining Dimn 21.20-0.25 mm found up to 20.73~20.95 mm |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 2 |
| 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 |
1500
|
0
|
0
|
1000
|
1500
|
4000
|
| Check Qty |
1500
|
0
|
0
|
1000
|
1500
|
4000
|
| NG Qty |
2
|
0
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| 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 | CNC 1st Set-up |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | CNC N0.01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Component was not clamp proper | Resting area of component was checked | X |
| Man | Training not given to operator | Training plan and on job training record checked | O |
| Man | Attitude of Operator is not good against work | Interview with operator found ok | O |
| Material | Damage on Component Resting area | Trial taken for damage component found NG | X |
| Machine | Jaw Clamping pressure was low | Jaw clamping pressure found ok | O |
| Man | Low skill level operator on Machine | Skill matrix chart verify found ok | O |
| Tool | Jaw runout is not ok | Set-up approval report checked found as per control plan | O |
| Tool | Burr on Component resting area in jaw | Air gun available on CNC machining stage | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 |
7. Root Cause Analysis (Occurance)
| Why 1 | Tapper Machining Dim 21.20-0.25 mm found up to 20.73~20.95 mm |
| Why 2 | Component was not clamp proper |
| Why 3 | Damage on Component Resting area |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Damage on Component Resting area |
Root Cause Analysis (Outflow)
| Why 1 | Inspection Eye sequence chart not updated at fettling stage |
| Why 2 | This defect not added |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspection Eye sequence chart not updated at fettling stage |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1. Rubber mat provided in casting stage. 2.Work instruction is updated for fettling operation damage defect checking and kept on red bin. | Production Supervisor | 19/06/2023 | 21/06/2023 | Completed |
| Outflow | 1.QA Alert displayed on Final stage 2.OPL displayed Casting,Fettling & Machining stage 3.Training given to Operator & Final Inspector. | QA Engineer | 20/06/2023 | 21/06/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NO |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 1:25 |
10. Evidance of Countermeasure
| Occurance (Before) |
Work Instruction not updated for fettling operation 488_Occurance_Before.jpg |
| Occurance (After) |
1. Rubber mat provided in casting stage. 2.Work instruction is updated for fettling operation damage defect checking and kept on red bin. 488_Occurance_After.pdf |
| Outflow (Before) |
Training and awareness not given to inspector and operator about defect 488_Outflow_Before.jpeg |
| Outflow (After) |
1.QA Alert displayed on Final stage 2.OPL displayed Casting,Fettling & Machining stage 3.Training given to Operator & Final Inspector. 488_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | no |
12. Document Review
| Documents | WISOP, InspCheckSheet |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | OK |