QFR No - 8000854740
Defect Details
| NC No. | 8000854740 |
| NC Date | 12/12/2023 |
| NC Submission Date | |
| Part No. | B2SU01002O |
| Part Name | BRAKE HOSE TUBE CLAMP 2 (N282) |
| Supplier Name & Code | 100151-EXCELL PRESSINGS |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | OTHER-BENDING NOT OK |
1. Problem Description
| Defect Description | BENDING NOT OK |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 393 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | excellpressings.qc@gmail.com |
| Plant Head/CEO Email ID | yogesh_vaidya42@yahoo.co.in |
| MD Email ID | excellpressings@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
4000
|
0
|
0
|
3000
|
2000
|
9000
|
| Check Qty |
4000
|
0
|
0
|
3000
|
2000
|
9000
|
| NG Qty |
393
|
0
|
0
|
0
|
0
|
393
|
| Scrap | 393 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% inspection is done at ETL end and our end also |
3. Process Flow
| Process Flow Description |
|---|
| Blanking& piercing- Z bending- Lug bending- U bending- Final Forming |
4. Process Details
| Process / Operation | press operation |
| Outsource | No |
| Machine / Cell | EP-04 |
| Machine / Cell No. | EP-04 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Old location pin was wear out | Due to wear out location pin, ,movement took place of part on die | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10 |
7. Root Cause Analysis (Occurance)
| Why 1 | Hole not macthed after full closing at ETL end |
| Why 2 | In U bending operations, movement took place |
| Why 3 | location pin was wear out |
| Why 4 | New operator was on machine at U Bending operations |
| Why 5 | That operator was not aware about the location pin wear out |
| Root Cause (Occurance) | In U bending operation, shifting took place due to location pin wear out |
Root Cause Analysis (Outflow)
| Why 1 | Full closing operation is take place at ETL end |
| Why 2 | Partial closing at our end, cant check every job by doing full closing at our end |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Every job full closing cant be done at our end, as we have to supply partial closing job. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | New location pin will be provided, so that movement cant be take place | Nikhil Ghodmare & Ankosh Mathure | 20/12/2023 | 20/12/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Sampling of folding jobs at our end will be increased |
| Inspection Method | Other |
| Other Inspection Method | Rod & block |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10 |
10. Evidance of Countermeasure
| Occurance (Before) |
location pin wear out 614_Occurance_Before.jpg |
| Occurance (After) |
old location pin changed and new one added 614_Occurance_After.jpg |
| Outflow (Before) |
Hole not meet after full closing at ETL end 614_Outflow_Before.jpg |
| Outflow (After) |
Hole meet after full closing 614_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | At Excell pressings, hole should be matched after full closing |
12. Document Review
| Documents | PMCheckSheet, JHCheckSheet, InspCheckSheet |
| Specify Other Document | FFPA checksheet |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | No defect found in latest lot |