QFR No - 8000834724
Defect Details
| NC No. | 8000834724 |
| NC Date | 27/06/2023 |
| NC Submission Date | |
| Part No. | S2AB02207B |
| Part Name | ADJUSTER POWDER COATED KTEM |
| Supplier Name & Code | 100973-TESMO MOTORCAST PRIVATE LIMITE |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | EXCESS MATERIAL-EXCESS MATERIAL AT SPRING RESTING FACE |
1. Problem Description
| Defect Description | Excess material observed at spring resting face. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 19 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
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 |
2000
|
0
|
0
|
3000
|
10000
|
15000
|
| Check Qty |
2000
|
0
|
0
|
3000
|
5000
|
10000
|
| NG Qty |
20
|
0
|
0
|
2
|
300
|
322
|
| Scrap | 20 |
| Rework | 302 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1). Pin flash rework process started. 2). 100% inspection before powder coating. |
3. Process Flow
| Process Flow Description |
|---|
| C-REAMER-GRINDING-SURFACE TREATMENT-INSPECTION-POWDER COATING-SAMPLE INSPECTION-PACKING DESPATCH |
4. Process Details
| Process / Operation | PDC |
| Outsource | No |
| Machine / Cell | HPDC MACHINE |
| Machine / Cell No. | 350-1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | INSERT MATERIAL NOT GOOD | CHEMICAL COMPOSITION VARIFICATION | O |
| Machine | EJECITON NOT BALANCE | VISUAL CHECK FOR EJECTION PARALLILITY | O |
| Tool | EJECTOR PIN DIA ON MOVING INSERT INCREASES | VERNIER | 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 | 1 |
7. Root Cause Analysis (Occurance)
| Why 1 | PIN FLASH ON SPRING RESTING FACE |
| Why 2 | EJECTOR PIN INCREASE ON INSERT |
| Why 3 | DIE RUNNING WITH UNBALANCE EJECTION |
| Why 4 | SETTING NOT DONE CORRECTLY |
| Why 5 | POOR SKILL LEVEL |
| Root Cause (Occurance) | EJECTOR SETTING SKILL LEVEL NOT GOOD |
Root Cause Analysis (Outflow)
| Why 1 | PIN FLASH ON SPRING RESTING FACE |
| Why 2 | PIN FLASH CHECKING IS MISSED BY INSPECTOR |
| Why 3 | IMPROPER TRAINING TO INSPECTOR |
| Why 4 | VISUAL DISPLAY NOT AVAILABLE |
| Why 5 | |
| Root Cause (Outflow) | VISUAL DISPLAY OF PIN FLASH NOT AVAILABLE |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | PIN & DIAMETER CHECKING | SACHIN | 15/07/2023 | 15/07/2023 | Completed |
| Occurance | VISUAL DISPLAY AT INSPECTION WITH PROPER TRAINING | RAHUL KHARE | 15/07/2023 | 15/07/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | VISUAL DISPLAY IN INSPECTION TABLE WITH SAMPLE |
| Inspection Method | Other |
| Other Inspection Method | VISUAL |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1 |
10. Evidance of Countermeasure
| Occurance (Before) |
PART WITH PIN FLASH 500_Occurance_Before.jpg |
| Occurance (After) |
EJECTOR PIN DIA INCREASE 500_Occurance_After.jpg |
| Outflow (Before) |
PART WITH PIN FLASH 500_Outflow_Before.jpg |
| Outflow (After) |
SAMPLE PLACED ON FINAL STAGE 500_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NO |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | PART DISPLAY |
13. Effectiveness Of Action
| Reviewed Quantity | 10 |
| Reason for submission | Against reported defect. |