QFR No - 8000835012
Defect Details
| NC No. | 8000835012 |
| NC Date | 30/06/2023 |
| NC Submission Date | |
| Part No. | C2PP00320B |
| Part Name | WHEEL CLUTCH_C20009_D1 |
| Supplier Name & Code | 100432-BHAKTI AUTO COMP PRIVATE LIMIT |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | TAPPING O/SIZE.-THREADING OVERSIZE ISSUE(PPG NOGO QUALIF |
1. Problem Description
| Defect Description | Threading Oversize -Fitment bolt loose (Minor Diameter found oversize) |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 32 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | bhaktiauto2008@gmail.com |
| Plant Head/CEO Email ID | bhaktiauto2008@gmail.com |
| MD Email ID | vinodanin@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
400
|
0
|
0
|
400
|
800
|
1600
|
| Check Qty |
400
|
0
|
0
|
400
|
800
|
1600
|
| NG Qty |
32
|
0
|
0
|
0
|
0
|
32
|
| Scrap | 32 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% lot verified at customer end Inhouse WIP & FG stock verified |
3. Process Flow
| Process Flow Description |
|---|
| Raw Material - Melting - Casting - Fettling - Face machining -6 hole Drill & Tapping - Inspection - PDI - Dispatch |
4. Process Details
| Process / Operation | Drilling & Tapping |
| Outsource | Yes |
| Machine / Cell | machining |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | part loading on fixture | part loose after claming | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 |
7. Root Cause Analysis (Occurance)
| Why 1 | Part No load properly on fixture |
| Why 2 | Operator not able to judge the perfect loading of part on fixture |
| Why 3 | Entry Level L1 Operator |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Part uneven clamping on fixture by semi skilled operator, Drilling hole shifted from its original lug position hence cause Minor ID Oversized |
Root Cause Analysis (Outflow)
| Why 1 | at final inspection stage inspector not able to detect the oversized issue |
| Why 2 | No check point for Minor ID inspection |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Check point is not available hence not able to block defect in inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Skilled Manpower L3 allotted to D/T Operation. | GS engineering | 08/07/2023 | 07/07/2023 | Completed |
| Outflow | Inspection check point added | Bhakti Auto | 07/07/2023 | 07/07/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | M6x1 Minor ID inspection check point is added in check sheet |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Semi Skilled operator 502_Occurance_Before.bmp |
| Occurance (After) |
skilled operator Provided 502_Occurance_After.bmp |
| Outflow (Before) |
No Check Point 502_Outflow_Before.jpg |
| Outflow (After) |
Check Point added in Inspection 502_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | Control plan |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | No repetition of Defect phenomenon |