QFR No - 8000863226
Defect Details
| NC No. | 8000863226 |
| NC Date | 16/02/2024 |
| NC Submission Date | |
| Part No. | S2JL05733B |
| Part Name | PISTON ROD BOTH SIDE M/C _MY 18 |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | DIMETER UNDERSIZE-5.5-0.1 ID IUNDER SIZE |
1. Problem Description
| Defect Description | Piston rod ID 5.5-01 found Under size |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 26 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@mahavirind.co.in |
| Plant Head/CEO Email ID | planthead@mahavirind.co.in |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
4200
|
0
|
0
|
1200
|
600
|
6000
|
| Check Qty |
4200
|
0
|
0
|
1200
|
600
|
6000
|
| NG Qty |
27
|
0
|
0
|
3
|
0
|
30
|
| Scrap | 27 |
| Rework | 3 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Suspected material verification at customer end |
3. Process Flow
| Process Flow Description |
|---|
| R/M Received- R/M Inward- band saw parting - straightening - 1st side chamfer-2nd side chamfer- 5mm Drilling-rough grinding- CNC-1st (Mounting)-CNC -2nd (Pist.side)- Cross hole Drilling- Cross Hole Chafer- IDF5.4 (1.4Cross hole) Burr Deburring - Final Inspection - Packing- Dispatch. |
4. Process Details
| Process / Operation | IDF5.4 (1.4Cross hole) Burr Deburring |
| Outsource | Yes |
| Machine / Cell | Drilling machine-1 |
| Machine / Cell No. | Drilling Section |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Hard burr At Main ID5.4 Hole of Cross Hole 1.4 | Cross Hole Hard burr Remove by machine stop condition on Drilling Machine. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Main ID 5.4mm under size |
| Why 2 | Heavy burr occurred at main id During cross hole 1.4mm Drilling Process. |
| Why 3 | Occurred Burr Remove By 5.4 Reamer as Machine standing condition. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Occurred Burr Remove By 5.4 Reamer as Machine standing condition. |
Root Cause Analysis (Outflow)
| Why 1 | Main ID 5.4mm under size |
| Why 2 | Sampling basis ID parameters verification By PPG After burr remove process on Drilling Machine. |
| Why 3 | Gauge Not Available on ID 5.4 Main hole ( Cross Hole) Deburring Process Stage. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Gauge Not Available on ID 5.4 Main hole ( Cross Hole) Deburring Process Stage. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Occurred Burr Deburring By 5.4 Reamer as Machine Running condition. | Line quality Incharge | 17/02/2024 | 22/02/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Main ID Inspection By New PPG on Deburring Stage. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Deburring Process Machine Stand Condition 680_Occurance_Before.pptx |
| Occurance (After) |
Deburring Process Machine Running Condition 680_Occurance_After.pptx |
| Outflow (Before) |
1)Sampling Basis ID inspection .2) PPG not available on deburring machine . 680_Outflow_Before.pptx |
| Outflow (After) |
1)100% ID Inspection On Deburring Process. 2) PPG Arrange On Deburring Machine. 680_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Hallow Piston Rod |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 1200 |
| Reason for submission | no any issue observed after action taken. |