QFR No - 8000834816
Defect Details
| NC No. | 8000834816 |
| NC Date | 29/06/2023 |
| NC Submission Date | |
| Part No. | S2BG02502B |
| Part Name | BRACKET UN P/C KTEP |
| Supplier Name & Code | 100973-TESMO MOTORCAST PRIVATE LIMITE |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | BROKEN-BROKEN AT BUSH FITTING STAGE |
1. Problem Description
| Defect Description | Part Broken during assembly condition. This is very serious as well as safety critical concern, & may leads to field complaint. |
| Detection Stage | Inprocess |
| Problem Severity | Safety |
| NG Quantity | 2 |
| 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 |
3000
|
0
|
0
|
3000
|
4000
|
10000
|
| Check Qty |
3000
|
0
|
0
|
3000
|
4000
|
10000
|
| NG Qty |
0
|
0
|
0
|
0
|
1
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Checking started in final stage with dot mark at bottom side |
3. Process Flow
| Process Flow Description |
|---|
| PDC - REAMER - DEBURRING - INSPECTION - SURFACE TREATMENT - CHAMFER - TAPPING - PACKING |
4. Process Details
| Process / Operation | PDC |
| Outsource | No |
| Machine / Cell | DIE CASTING MACHINE |
| Machine / Cell No. | 250-02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | CORE OUT INCOMPLETE | PHYSICAL | O |
| Method | EJECTION UNEVEN | VISUAL | 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 | Part cracked from its I-section |
| Why 2 | I-section area get weak due to hair crack generation |
| Why 3 | Part get tilted in hot condition while ejection process in PDC |
| Why 4 | Core not completely out and ejection done |
| Why 5 | Core slider Jam due to flash inside core sliding area |
| Root Cause (Occurance) | Machine run with flash in core area. |
Root Cause Analysis (Outflow)
| Why 1 | Cracked part found at customer end |
| Why 2 | Crack not checked |
| Why 3 | KTEP parts particular location crack checking not happening in final stage |
| Why 4 | Checking points not provided |
| Why 5 | |
| Root Cause (Outflow) | Point not available in check point of inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Crack check point added in inspection | Ankush | 29/06/2023 | 30/06/2023 | Completed |
| Occurance | Tool to run with flash free | Ravi | 28/06/2023 | 30/06/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Crack checking for this specific location incorporated in final inspection |
| 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) |
Flash at core side 498_Occurance_Before.jpeg |
| Occurance (After) |
Zero flash 498_Occurance_After.jpeg |
| Outflow (Before) |
Cracked Part 498_Outflow_Before.jpeg |
| Outflow (After) |
Quality Alert Displayed 498_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | KWPK |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | Alert displayed |
13. Effectiveness Of Action
| Reviewed Quantity | 10 |
| Reason for submission | Corrective action parts submission. |