QFR No - 8000860135
Defect Details
| NC No. | 8000860135 |
| NC Date | 23/01/2024 |
| NC Submission Date | |
| Part No. | S2BG00702B |
| Part Name | BRACKET UN P/C |
| Supplier Name & Code | 100973-TESMO MOTORCAST PRIVATE LIMITE |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | THREADING NOT OK-BRACKET PERPENDI. 3.98MM AGAINST 0.25 MM |
1. Problem Description
| Defect Description | Bracket Perpendicularity found up to 3.98 mm against 0.25mm with respect to M9 thread |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 2 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | 15plfd5vcoimbjgdpc2mlgki.jpg |
Supplier Communication Details
| Quality Head Email ID | harish.bala@tesmomotorcast.com |
| Plant Head/CEO Email ID | harish.bala@tesmomotorcast.com |
| MD Email ID | svkallani@tesmomotorcast.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
15000
|
12000
|
0
|
0
|
0
|
27000
|
| Check Qty |
15000
|
12000
|
0
|
0
|
0
|
27000
|
| NG Qty |
548
|
0
|
0
|
0
|
0
|
548
|
| Scrap | 548 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Stargate all parts and strengthen our final quality stages |
3. Process Flow
| Process Flow Description |
|---|
| PDC - Inspection - Deburring - Grinding - Buffing - Tapping - Inspection. |
4. Process Details
| Process / Operation | Die Casting |
| Outsource | No |
| Machine / Cell | PDC |
| Machine / Cell No. | PDC-250 ton. |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Insert internal diameter ovr size | Found at line, checked by verniew | O |
| Tool | Core Pin side undersize | Verniew | 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 | Bracket Perpendicularity found more than 0.25mm of M9 thread |
| Why 2 | M9 thread not perpendicular in tapping |
| Why 3 | Insert fitted not completely on parts |
| Why 4 | Insert get tilted in die casting process |
| Why 5 | Insert and Core pin clearance was more |
| Root Cause (Occurance) | Insert ID oversize, which not identified in lot sampling 5-from 1000nos. |
Root Cause Analysis (Outflow)
| Why 1 | More than 0.25mm, M9 Thread Perpendicularity found at customer end |
| Why 2 | Parts skipped from final inspections |
| Why 3 | Perpendicularity checking frequency was very low, checking by mandrill. |
| Why 4 | On line checking process in final stage not available |
| Why 5 | |
| Root Cause (Outflow) | Perpendicularity checking frequency increased. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Insert inward inspecting sampling quantity increased from 5 to 50 nos | Inward Quality | 29/01/2024 | 04/03/2024 | Completed |
| Outflow | Checking frequency increases in final stage | Final Quality Engr | 29/01/2024 | 04/03/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inward insert quality checking nos per lot increases from 05 to 50 nos |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 50 |
10. Evidance of Countermeasure
| Occurance (Before) |
Bracket Perpendicularity found more than 0.25mm of M9 thread 650_Occurance_Before.jpg |
| Occurance (After) |
Inwards inspection sampling size increases from 05 to 50 nos, also marking on each bags with approval on request note. 650_Occurance_After.jpeg |
| Outflow (Before) |
Perpendicularity checking frequency less & checked with mandrill. Checking process not available in final stage 650_Outflow_Before.mp4 |
| Outflow (After) |
Simple checking process implemented in final inspection stage as well as train multiple members for this process. 650_Outflow_After.mp4 |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | KTEP, KWPK |
12. Document Review
| Documents | WISOP, InspCheckSheet |
| Specify Other Document | Inspection |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | OK |