QFR No - 8000851228
Defect Details
| NC No. | 8000851228 |
| NC Date | 07/11/2023 |
| NC Submission Date | |
| Part No. | 165FZ00322 |
| Part Name | HUB CLUTCH BROACHED JW/BM-150 |
| Supplier Name & Code | 101100-CAST 4 ALUMINIUM PVT LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | CRACKS-CRACK ISSUE |
1. Problem Description
| Defect Description | Hub Clutch observed crack (Repeated occurrence ) |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 2 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | h1etbmobscijlsy1xp32ecw3.jpg |
Supplier Communication Details
| Quality Head Email ID | info@cast4aluminium.com |
| Plant Head/CEO Email ID | info@cast4aluminium.com |
| MD Email ID | kiran@cast4aluminium.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2268
|
0
|
0
|
7000
|
0
|
9268
|
| Check Qty |
2268
|
0
|
0
|
7000
|
0
|
9268
|
| NG Qty |
4
|
0
|
0
|
7
|
0
|
11
|
| Scrap | 11 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done for 7000 nos of JW hub at cast 4 end from which 7 parts are found for crack. |
3. Process Flow
| Process Flow Description |
|---|
| RM--->Melting--->Cleaning--->Cleaning--->PDC |
4. Process Details
| Process / Operation | PDC |
| Outsource | No |
| Machine / Cell | PDC Machine |
| Machine / Cell No. | PDC M/C No. |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Erosion mark | Yes, possible | O |
| Machine | Excess clamping pressure of CNC Chuck | Yes, possible | O |
| Tool | Scoring mark on die | Yes, possible | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Crack Observed on the friction face of JW Hub. |
| Why 2 | Cracks observed at same position i.e. on the Gate Area side and in the cavity no. 3 only. |
| Why 3 | Casting was getting stuck in the die while ejecting . |
| Why 4 | Scoring observed in the die and excess rubbing mark observed on the part. |
| Why 5 | Erosion mark observed near gate area & scoring on die. |
| Root Cause (Occurance) | Erosion mark observed near gate area & scoring on die. |
Root Cause Analysis (Outflow)
| Why 1 | Crack part found at ETL. |
| Why 2 | Crack was not identified by the two inspectors only. |
| Why 3 | Training was given to all of the inspectors still these two inspector was not able to detect the crack part. |
| Why 4 | Training effectiveness was not monitored |
| Why 5 | |
| Root Cause (Outflow) | Training effectiveness was not monitored |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1. Die polishing done while PM. 2. New die planning will be done on the priority basis. | 1. Die maint. team 2. Top management | 17/11/2023 | 17/11/2023 | Completed |
| Outflow | 1. One Point lesson displayed and training given to the inspectors 2. Training effectiveness monitoring for these two inspectors will be planed. 4. For crack checking special marking is given. 5.Part is being checked under the magnifying glass 6.DP test on the gate area will be done on the sampling basis. | Mr. Qasim | 10/11/2023 | 10/11/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Part is being checked under the magnifying glass |
| Inspection Method | Other |
| Other Inspection Method | Visual Inpection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Scoring mark on die 590_Occurance_Before.png |
| Occurance (After) |
Die polishing done while PM. 590_Occurance_After.jpeg |
| Outflow (Before) |
NA 590_Outflow_Before.png |
| Outflow (After) |
Part is being checked under the magnifying glass 590_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | PMCheckSheet, PFMEA, WISOP |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | OK |