QFR No - 8000843595
Defect Details
| NC No. | 8000843595 |
| NC Date | 07/09/2023 |
| NC Submission Date | |
| Part No. | B2GQ01903O |
| Part Name | MASTER CYLINDER RAW CASTING- C101 H |
| Supplier Name & Code | 100398-MANOJ INDUSTRIES |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | BLOW HOLES-LEAKAGE AT CUSTOMER END |
1. Problem Description
| Defect Description | Leakage |
| Detection Stage | Customer End |
| Problem Severity | Safety |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qad@manojindustrieskop.com |
| Plant Head/CEO Email ID | foundry@manojindustrieskop.com |
| MD Email ID | mgnt@manojindustrieskop.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1300
|
0
|
0
|
0
|
0
|
1300
|
| Check Qty |
1300
|
0
|
0
|
0
|
0
|
1300
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| ---- |
3. Process Flow
| Process Flow Description |
|---|
| Casting production |
4. Process Details
| Process / Operation | Casting production |
| Outsource | No |
| Machine / Cell | MI Tilt -19 |
| Machine / Cell No. | MI Tilt -19 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Die modification |
| Check Point at Final Inspection | No |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Leakage observed at customer end. |
| Why 2 | Shrinkage porosity observed at below barrel OD at corner radius |
| Why 3 | Improper feeding of material at barrel OD area |
| Why 4 | Due to cross sectional variation shrinkage porosity observed. |
| Why 5 | |
| Root Cause (Occurance) | Due to cross sectional variation shrinkage porosity observed. |
Root Cause Analysis (Outflow)
| Why 1 | Leakage observed at customer end. |
| Why 2 | Defect not seen by nacked eyes |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | --- |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | We are adding extra feeder as per proposed action it will help to feed the casting below lug area | D B LAD | 21/09/2023 | 29/09/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | no change |
| Inspection Method | Other |
| Other Inspection Method | DP test done |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | daily |
10. Evidance of Countermeasure
| Occurance (Before) |
Leakage observed at bellow lug area 542_Occurance_Before.png |
| Occurance (After) |
We are adding extra feeder as per proposed action it will help to feed the casting below lug area 542_Occurance_After.png |
| Outflow (Before) |
Leakage observed at bellow lug area 542_Outflow_Before.png |
| Outflow (After) |
--- 542_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All C101 master cyl |
12. Document Review
| Documents | |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | NO leakage found in received lot |