QFR No - 8000859512
Defect Details
| NC No. | 8000859512 |
| NC Date | 19/01/2024 |
| NC Submission Date | |
| Part No. | 520KT00102 |
| Part Name | ROD BUSH |
| Supplier Name & Code | 100176-GKN SINTER METALS PRIVATE LIMI |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | MATERIAL DEFECT-CRACK ISSUE |
1. Problem Description
| Defect Description | Rod bush crack issue |
| Detection Stage | Inprocess |
| Problem Severity | Safety |
| NG Quantity | 272 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | Rajendra.Sethiya@gknpm.com |
| Plant Head/CEO Email ID | Pratik.Dharangaonkar@gknpm.com |
| MD Email ID | Rajesh.Mirani@gknpm.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
46000
|
0
|
0
|
23000
|
0
|
69000
|
| Check Qty |
46000
|
0
|
0
|
23000
|
0
|
69000
|
| NG Qty |
274
|
0
|
0
|
0
|
0
|
274
|
| Scrap | 274 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Stock lying at ETL end & GKN end segregated for crack issue. |
3. Process Flow
| Process Flow Description |
|---|
| Mixing-Forming-Sintering-Heat Treatment-Barreling-Final Inspection-PDI |
4. Process Details
| Process / Operation | Forming |
| Outsource | No |
| Machine / Cell | Forming Press |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Forming material handling inadequate | Material is handled in plywood trays at forming stage | X |
| Man | Unskilled Operator | Skill matrix verified, found OK | O |
| Tool | Wrong tools used | Tools report verified, found OK | O |
| Material | Raw material NG | RM Test report verified, found OK | O |
| Material | Density NG | MTR Verified, found OK | O |
| Material | Hardness NG | MTR Verified, found OK | O |
| Machine | Machine breakdown | In process reports verified, found OK | 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 in rod bush |
| Why 2 | Crack got generated during handling of material at sintering stage |
| Why 3 | During forming to sintering material handled plywood trays |
| Why 4 | During sintering material loaded in wire mesh trays from plywood trays |
| Why 5 | |
| Root Cause (Occurance) | During sintering material loaded in wire mesh trays from plywood trays |
Root Cause Analysis (Outflow)
| Why 1 | Crack observed in rod bush |
| Why 2 | Crack part skipped from visual inspection |
| Why 3 | No check point available at final inspection |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No check point available at final inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Awareness training given to concern operators to use wire mesh trays instead of plywood trays | Mr. Rohan G | 15/04/2024 | 13/04/2024 | Completed |
| Outflow | Checkpoint added at final inspection WI | Mr. B Avhad | 15/04/2024 | 13/04/2024 | Completed |
| Occurance | From forming to sintering material will be handled in wire mesh trays instead of plywood trays | Mr. Rohan G | 15/04/2024 | 13/04/2024 | Completed |
| Outflow | Awareness training given to concern persons | Mr. B Avhad | 15/04/2024 | 13/04/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NA |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
10. Evidance of Countermeasure
| Occurance (Before) |
Plywood trays used 642_Occurance_Before.pptx |
| Occurance (After) |
Wire mesh trays implemented 642_Occurance_After.pptx |
| Outflow (Before) |
No check point 642_Outflow_Before.ppt |
| Outflow (After) |
Check point added 642_Outflow_After.ppt |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | problem in rod bush but in action plan photo piston |