QFR No - 8000835556
Defect Details
| NC No. | 8000835556 |
| NC Date | 06/07/2023 |
| NC Submission Date | |
| Part No. | S2MX01312B |
| Part Name | STEEL BUSH (MFeZn8-S) |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | EXCESS MATERIAL-SHARP EDGES ON FASE AND INCOMPETED M/C |
1. Problem Description
| Defect Description | Sharp Edges on face & parting operation incomplete |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 24 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | l12lv4vlupzt0yklncgm1hwb.png |
Supplier Communication Details
| Quality Head Email ID | quality@mahavirind.co.in |
| Plant Head/CEO Email ID | planthead@mahavirind.co.in |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5000
|
5000
|
0
|
0
|
0
|
10000
|
| Check Qty |
5000
|
5000
|
0
|
0
|
0
|
10000
|
| NG Qty |
24
|
0
|
0
|
0
|
0
|
24
|
| Scrap | 24 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Suspected Material Segregation at Customer End |
3. Process Flow
| Process Flow Description |
|---|
| Raw Material Inward - Store-Parting On Traub- Second Side Chamfer - Plating- Final Inspection - Dispatch |
4. Process Details
| Process / Operation | Second Side Chamfer |
| Outsource | Yes |
| Machine / Cell | Drilling Machine-2 |
| Machine / Cell No. | Chamfer Secton |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Manual 2nd side Chamfer Process On Drill Machine | Defected Parts Skipped During Manual Chamfer process. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | EXCESS MATERIAL-SHARP EDGES ON FASE AND INCOMPETED M/C |
| Why 2 | On Chamfering Machine 2nd Operation - Randomly part skipped by operator . |
| Why 3 | During Manual Chamfer process operational part catch by plier on Drilling Machine. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | During Manual Chamfer process operational part catch by plier on Drilling Machine. |
Root Cause Analysis (Outflow)
| Why 1 | EXCESS MATERIAL-SHARP EDGES ON FASE AND INCOMPETED M/C |
| Why 2 | By Mistake Defected parts Mix By Final Inspector . |
| Why 3 | Sampling Base Final Inspection For Visual Inspection |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Sampling Base Final Inspection For Visual Inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Chamfer Process Change | Plant Head | 08/07/2023 | 08/07/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Visual Inspection Start Before Dispatch |
| Inspection Method | Other |
| Other Inspection Method | 100% Visual Insp. |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
During 2nd Chamfer operation part Mounting by plier 505_Occurance_Before.docx |
| Occurance (After) |
During 2nd Chamfer operation Part Mounting in Three Jaw Chuck 505_Occurance_After.docx |
| Outflow (Before) |
Before Sampling Base Visual Inspection 505_Outflow_Before.docx |
| Outflow (After) |
Now 100% Visual at Final inspection Stage. 505_Outflow_After.docx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Steel Bush |
12. Document Review
| Documents | ControlPlan, PFMEA, ProcessFlowChart |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | ok |