QFR No - 8000847104
Defect Details
| NC No. | 8000847104 |
| NC Date | 03/10/2023 |
| NC Submission Date | |
| Part No. | 520PP01902 |
| Part Name | WHEEL CLUTCH FINISHED UPGRADE |
| Supplier Name & Code | 100656-MADHURA DIE CAST PVT.LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | RUN OUT MORE-FITMNET ISSUE DUE TO TEETH R/O UPTO 1 MM |
1. Problem Description
| Defect Description | Customer Return -Fitment issue due to teeth run out found up to 1.15 mm against 0.2 mm |
| Detection Stage | Customer End |
| Problem Severity | Fitment |
| NG Quantity | 2 |
| Is Defect Repeatative? | No |
| 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 |
1000
|
0
|
0
|
500
|
600
|
2100
|
| Check Qty |
1000
|
0
|
0
|
500
|
600
|
2100
|
| NG Qty |
2
|
0
|
0
|
1
|
1
|
4
|
| Scrap | 4 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% SEGERATION DONE AT SUPPLIER END STARTED BLUE IDENTIFICATION DOT MARK ON COMPONENTS |
3. Process Flow
| Process Flow Description |
|---|
| 1.Casting 2.fetling 3. CNC 1st Set-up 4.CNC 2nd Set-up 5.Drilling & Tapping 6.Final Inspection |
4. Process Details
| Process / Operation | CNC 1ST Set-up |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | 06 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskill operator operate machine | Skill matrix verify found ok | O |
| Material | Wrong grade Material is used | Verified & Found OK | O |
| Method | Input & output material bin not identified on CNC stage | Verified & Found ok | O |
| Machine | Jaw clamping pad area in CNC chuck got wear | Found Not OK | X |
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 | Fitment issue due to teeth run out found up to 1.15 mm against 0.2 mm |
| Why 2 | CNC machine chuck Jaw abnormal clamping |
| Why 3 | out of three one jaw got play during clamping |
| Why 4 | Jaw clamping pad area in CNC chuck got wear |
| Why 5 | Jaw clamping area play found upto 0.15 mm. |
| Root Cause (Occurance) | Jaw clamping pad area in CNC chuck got wear |
Root Cause Analysis (Outflow)
| Why 1 | Fitment issue due to teeth run out found up to 1.15 mm against 0.2 mm |
| Why 2 | Teeth Runout checking not checking at Final stage |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Teeth Runout checking not checking at Final stage |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 1. Started 100% Inspection with attribute type teeth runout Checking gauge at Final stage. 2. Also Fitment checking parameter with meeting part 3W4S hub added in final inspection check sheet. 3. Inspection Agreement & PDIR is revised for 100% inspection with attribute type teeth runout gauge. 4. Started doc audit daily basis & data maintained . | Quality Supervisor | 05/10/2023 | 05/10/2023 | Completed |
| Occurance | 1.New chuck is provided & old chuck is send for reconditioning . 2.Started Jaw Clamping (Working condition ) Verification on daily JH Activity . 3.PM Plan revised Mentioned specific dimension of chuck guide area 14 mm tolerance upto, +H7(0.025mm). 4.Started Chuck Inspection by using master Ring & dial stand point verified in daily JH activity. 5.Jaw Boring frequency is define in PM Check sheet & its monitoring started. 6.Clamping pressure validation started interlock given to chuck clamping pressure. 7.New attribute Relation gauge manufacturing is started . Mgf .Target Date – 05.11.2023 8.Customer complain action sustenance verification register maintain.9.Special Jaw Chuck to be implemented at CNC Machining to avoid part shift & Achieve teeth runout . | Production Supervisor | 15/10/2023 | 05/10/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Started 100% Inspection with attribute type teeth runout Checking gauge at Final stage. Also Fitment checking parameter with meeting part 3W4S hub added in final inspection check sheet. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:10 |
10. Evidance of Countermeasure
| Occurance (Before) |
Jaw clamping pad area in CNC chuck got wear 561_Occurance_Before.jpg |
| Occurance (After) |
.1.New chuck is provided & old chuck is send for reconditioning . 2.Started Jaw Clamping (Working condition ) Verification on daily JH Activity . 3.PM Plan revised Mentioned specific dimension of chuck guide area 14 mm tolerance upto, +H7(0.025mm). 4.Started Chuck Inspection by using master Ring & dial stand point verified in daily JH activity. 5.Jaw Boring frequency is define in PM Check sheet & its monitoring started. 6.Clamping pressure validation started interlock given to chuck clamping pressure. 7.New attribute Relation gauge manufacturing is started . Mgf .Target Date – 05.11.2023 8.Customer complain action sustenance verification register maintain.9.Special Jaw Chuck to be implemented at CNC Machining to avoid part shift & Achieve teeth runout . 561_Occurance_After.xlsx |
| Outflow (Before) |
Teeth Runout checking not checking at Final stage 561_Outflow_Before.mp4 |
| Outflow (After) |
Started 100% Inspection with attribute type teeth runout Checking gauge at Final stage. Also Fitment checking parameter with meeting part 3W4S hub added in final inspection check sheet. 561_Outflow_After.jfif |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | 3W4S WHEEL CLUTCH FINISHED UPGRADE |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, PFMEA, JHCheckSheet, InspCheckSheet |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 10000 |
| Reason for submission | OK |