QFR No - 8000855363
Defect Details
| NC No. | 8000855363 |
| NC Date | 18/12/2023 |
| NC Submission Date | |
| Part No. | 520JT00302 |
| Part Name | PLATE CLUTCH 3W-4S UPGRADE |
| Supplier Name & Code | 100150-DHANANJAY ENTERPRISES |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | THICKNESS UNDERSIZE-THICKNESS U/S UP TO 1.63 AGAINST 2.0 |
1. Problem Description
| Defect Description | Wrong Thickness observed in 3W4S Plate clutch (1.6 mm observed in 2 mm) |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 17 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qade@dhananjaygroup.com |
| Plant Head/CEO Email ID | de@dhananjaygroup.com |
| MD Email ID | kandakuretn@dhananjaygroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
19480
|
0
|
0
|
20160
|
0
|
39640
|
| Check Qty |
19480
|
0
|
0
|
20160
|
0
|
39640
|
| NG Qty |
22
|
0
|
0
|
52
|
0
|
74
|
| Scrap | 74 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregated whole lot at the M/s ETL end & our DE-I plant end. |
3. Process Flow
| Process Flow Description |
|---|
| Receiving inspection of RM?Blanking & Piercing?Deburring?Cleaning?Planishing?Straightening?Final Inspection?Oiling & Packing?Logistics/Dispatch |
4. Process Details
| Process / Operation | Blanking & Piercing |
| Outsource | No |
| Machine / Cell | Press Machine-Pnumatic 100T |
| Machine / Cell No. | Machine no.-10000063 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Set-up approval | Set-up approval not followed after RM coil change | X |
| Man | Man- Unskilled Operator | Unskilled operator for loading of coil | X |
| Man | Man- Wrong coil loading | Wrong thickness coil loading on D-coiler | X |
| Material | Material- RM Storage | No separate storage location for same width different thickness coils | X |
| Material | Material- Wrong thk. | Wrong material thickness coil loaded on D-coiler | X |
| Machine | Machine- Excess deburring | No excess deburring done on part | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05nos/lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Wrong thickness in Plate Clutch 3W4S |
| Why 2 | Required thickness 2 observed 1.6mm |
| Why 3 | Two packed form RM coils have same width but different thickness. |
| Why 4 | No separate storage location available. |
| Why 5 | |
| Root Cause (Occurance) | No separate storage location available. |
Root Cause Analysis (Outflow)
| Why 1 | Wrong thickness in Plate Clutch 3W4S |
| Why 2 | Required thickness 2 observed 1.6mm |
| Why 3 | Set up approval not done after RM Coil change. |
| Why 4 | Set-up approval done during changeover of part/die only. |
| Why 5 | RM coil loading approval report not considered in setting of new RM coil on D-Coiler in PFMEA |
| Root Cause (Outflow) | RM coil loading approval report not considered in setting of new RM coil on D-Coiler in PFMEA |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Separate location provided for same width-different thickness raw material coil | Mr. Nikhil Attarde | 30/12/2023 | 30/12/2023 | Completed |
| Occurance | Colour coding with blue & yellow paint colour according to thickness of same width different thickness RM coils to be ensured by incoming inspection person.Meantime the same to be informed to supplier for this colour codification. | Mr. Nikhil Attarde | 30/12/2023 | 30/12/2023 | Completed |
| Outflow | 100% inspection of material for thickness with Gap gauge started for next 1 month. | Mr. Nikhil Attarde | 30/12/2023 | 18/12/2023 | Completed |
| Outflow | Raw material coil loading approval report provided for every new coil loading on D-coiler. | Mr. Nikhil Attarde | 30/12/2023 | 30/12/2023 | Completed |
| Occurance | Training given to operator | Mr. Nikhil Attarde | 30/12/2023 | 20/12/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Gap-Gauge inspection started 100% for thickness mix-up detection for next one month |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05nos/lot |
10. Evidance of Countermeasure
| Occurance (Before) |
RM coils of same width and different thickness have no separate location available for storage. 618_Occurance_Before.jpg |
| Occurance (After) |
RM coils of same width and different thickness have allocated separate location for storage. 618_Occurance_After.jpg |
| Outflow (Before) |
Set-up approval report take for die-change & start of the shift only. 618_Outflow_Before.pdf |
| Outflow (After) |
RM coil loading approval report for every new coil loading on machine D-coiler. 618_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | N.A |
12. Document Review
| Documents | ControlPlan, PFMEA, InspCheckSheet |
| Specify Other Document | N.A |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | OK |