QFR No - 8000862173
Defect Details
| NC No. | 8000862173 |
| NC Date | 07/02/2024 |
| NC Submission Date | |
| Part No. | F2PD02007B |
| Part Name | UPPER BRACKET P/C-XF-1C1 |
| Supplier Name & Code | 100001-ANANT ENTERPRISES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | RUNOUT-BLOW HOLE, PIN HOLE AND CUT MARKS |
1. Problem Description
| Defect Description | Casting defects |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 50 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | anandkulkarni@anantgroup.co.in |
| Plant Head/CEO Email ID | pramodgosavi@anantgroup.co.in |
| MD Email ID | ashwinjoshi@anantgroup.co.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
200
|
0
|
0
|
150
|
100
|
450
|
| Check Qty |
200
|
0
|
0
|
150
|
100
|
450
|
| NG Qty |
50
|
0
|
0
|
19
|
0
|
69
|
| Scrap | 69 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % parts checked and identification mark provide on part. |
3. Process Flow
| Process Flow Description |
|---|
| Raw material received - Storage - Melting - Molten metal transfer to holding - Metal treatment - Die preparation - Casting - Cutting - grinding - Heat Treatment - Visual inspection - Powder coating - machining - final inspection - dispatch. |
4. Process Details
| Process / Operation | Casting, powder coating, & Machining. |
| Outsource | No |
| Machine / Cell | pF no 3 |
| Machine / Cell No. | GDC M/c |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | The operator was not skilled | Skill matrix | O |
| Material | Other material used | Ok material used | O |
| Machine | Solidification time reduced. | Timer check found ok | O |
| Method | Die coating process. | Air vent not cleaned die coat accumulated | X |
| Tool | other tool used | OK tool used. | O |
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 | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Pin hole due to turbulence |
| Why 2 | Turbulence due to air entrapment |
| Why 3 | Insufficient air vents |
| Why 4 | Die coat accumulated in air vent |
| Why 5 | Die coat not cleaned after coating apply. |
| Root Cause (Occurance) | Die coat not cleaned after coating apply. |
Root Cause Analysis (Outflow)
| Why 1 | Visual inspection not done. |
| Why 2 | Defect severity not aware. |
| Why 3 | Training in effective. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Training in effective. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Training provided to final inspectors. | Mr Nisar | 28/02/2024 | 28/02/2024 | Completed |
| Occurance | 1) Air vent cleaning frequency increased. 2) Periodically verification started. | Mr Sunil Monde | 28/02/2024 | 28/02/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% parts checked |
| Inspection Method | Other |
| Other Inspection Method | visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
PM check sheet before 669_Occurance_Before.pdf |
| Occurance (After) |
PM check sheet after 669_Occurance_After.pdf |
| Outflow (Before) |
No Training 669_Outflow_Before.pdf |
| Outflow (After) |
Training given to inspectors 669_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | no |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 210 |
| Reason for submission | Found ok |