QFR No - 8000854205
Defect Details
| NC No. | 8000854205 |
| NC Date | 08/12/2023 |
| 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 | HIGHT O/SIZE.-LUG HIGHT OBS 27.6+ AGAINST 26.60 +/-0.1 |
1. Problem Description
| Defect Description | Lug Height found oversize up to 27.38~27.6 mm against 26.60±0.1 mm |
| Detection Stage | Inprocess |
| 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 |
1000
|
500
|
0
|
500
|
500
|
2500
|
| Check Qty |
1000
|
500
|
0
|
500
|
500
|
2500
|
| NG Qty |
1
|
0
|
0
|
0
|
500
|
501
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Stock segregate at customer end and Supplier end stock. |
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 2ND SETUP |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | 07 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | chuck jaw loose | Checked found ok | O |
| Man | Unskill Operator On machine. | Skill Matrix Varified & Found OK. | O |
| Tool | Insert got wear | Checked found ok | O |
| Method | component shift | verified found not ok component shift due to extra material above OD. So face side got more cut. | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
7. Root Cause Analysis (Occurance)
| Why 1 | HIGHT O/SIZE.-LUG HIGHT OBS 27.6+ AGAINST 26.60 +/-0.1 |
| Why 2 | Extra cut on resting face of part during cnc 2nd setup machining |
| Why 3 | Part move & come in front side. |
| Why 4 | Because extra material found in Outer dia . |
| Why 5 | Then there is component shift due to extra material above OD. So face side got more cut. |
| Root Cause (Occurance) | Then there is component shift due to extra material above OD. So face side got more cut. |
Root Cause Analysis (Outflow)
| Why 1 | HIGHT O/SIZE.-LUG HIGHT OBS 27.6+ AGAINST 26.60 +/-0.1 |
| Why 2 | 100% Inspection not done |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspection done on sampling basis |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 1. Training & Awarness given to operator. 2. OPL is displayed. 3.Quality Alert is displayed. | QUALITY SUPERVISOR | 21/12/2023 | 20/12/2023 | Completed |
| Occurance | 1. Started 100 % inspection after fettling operation. 2. Correction done in CNC Program ,OD Cut increases. | PRODUCTION SUPERVISOR | 21/12/2023 | 20/12/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Started 100 % inspection after fettling operation. |
| Inspection Method | Other |
| Other Inspection Method | VISUAL |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
component shift due to extra material above OD. So face side got more cut. 611_Occurance_Before.jpg |
| Occurance (After) |
1. Started 100 % inspection after fettling operation.
2. Correction done in CNC Program ,OD Cut increases. 611_Occurance_After.pdf |
| Outflow (Before) |
100% Inspection not done 611_Outflow_Before.jpg |
| Outflow (After) |
1. Training & Awarness given to operator.
2. OPL is displayed.
3.Quality Alert is displayed. 611_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | QUALITY ALERT,OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | OK-Sustenance to be monitored |