QFR No - 8000844147
Defect Details
| NC No. | 8000844147 |
| NC Date | 12/09/2023 |
| NC Submission Date | |
| Part No. | 520FZ01002 |
| Part Name | HUB CLUTCH WITH INNER RING REML 6/7 PL |
| Supplier Name & Code | 100656-MADHURA DIE CAST PVT.LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | NOT AS PER SPECIFICATION-RING LOOSE |
1. Problem Description
| Defect Description | Warranty complaint -Ring Loose issue in Hub Clutch |
| Detection Stage | Warranty |
| Problem Severity | Function |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | madhuradiecast@gmail.com |
| Plant Head/CEO Email ID | madhuradiecast@gmail.com |
| MD Email ID | madhuradiecast@gaikegroup.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
500
|
1000
|
0
|
500
|
300
|
2300
|
| Check Qty |
500
|
1000
|
0
|
500
|
300
|
2300
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% segregation done at customer End & Supplier End. |
3. Process Flow
| Process Flow Description |
|---|
| 1.Casting 2.fetling 3. CNC 1st Set-up 4.CNC 2nd Set-up 5. Ring Pressing 6.Broaching 7. CNC OD Turning 6.Final Inspection |
4. Process Details
| Process / Operation | CNC |
| Outsource | No |
| Machine / Cell | CNC 2 ND SET UP |
| Machine / Cell No. | 06 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Due to overheated which inner ring id got expanded. | verified & found not ok | X |
| Tool | Jaw loose in running | Check and verify found ok | O |
| Man | Unskilled operator was operate machine | Skill Matrix is verified & found ok | O |
| Material | Burr on clamping area | Verify the component found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
7. Root Cause Analysis (Occurance)
| Why 1 | Ring Loose issue in Hub Clutch |
| Why 2 | Ring inner dia increased by 0.031 mm & outer dia increased by 0.022 mm |
| Why 3 | The Mating part (Bearing) resting on inner ring od got seized . |
| Why 4 | Due to overheated which inner ring id got expanded |
| Why 5 | |
| Root Cause (Occurance) | Due to overheated which inner ring id got expanded |
Root Cause Analysis (Outflow)
| Why 1 | Ring Loose issue in Hub Clutch |
| Why 2 | 100% inspection not done at all stages |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | 100% inspection not done at all stages |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 1. 100% inner ring id checking started at inward inspection with air gauge. 2. 100% id inspection with air gauge at load cell stage before ring pressing. 3. 100% inspection of inner ring outer dia at CNC Stage after grinding. 4. 100% inspection of inner ring outer dia at final inspection stage before dispatch. | Quality Supervisor | 15/10/2023 | 09/10/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | started 100% inner ring id & od Inspection at all stages |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
Action plan PPT is attached for this problem 551_Occurance_Before.pptx |
| Occurance (After) |
For complete root cause action & analysis we need to checked mating part(bearing) which is resting on inner ring OD 551_Occurance_After.jpg |
| Outflow (Before) |
100% inspection not done at all stages 551_Outflow_Before.xls |
| Outflow (After) |
1. 100% inner ring id checking started at inward inspection with air gauge. 2. 100% id inspection with air gauge at load cell stage before ring pressing. 3. 100% inspection of inner ring outer dia at CNC Stage after grinding. 4. 100% inspection of inner ring outer dia at final inspection stage before dispatch. 551_Outflow_After.xls |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | CNC |
12. Document Review
| Documents | ControlPlan, PFMEA, InspCheckSheet |
| Specify Other Document | QA ALERT |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |