QFR No - 8000863411
Defect Details
| NC No. | 8000863411 |
| NC Date | 17/02/2024 |
| NC Submission Date | |
| Part No. | 520FG07802 |
| Part Name | GEAR PRIMARY DRIVEN (JZ) |
| Supplier Name & Code | 200172-AURANGABAD AUTO ENGG PVT LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | PATCH MARK ON FACE.-DFC OBS 0.12 AGAINST 0.07 |
1. Problem Description
| Defect Description | Flicker observed excess up to 0.030 mm against 0.010 mm -DFCE observed 0.12 mm against 0.040 mm |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | verma.aaepl@gmail.com |
| Plant Head/CEO Email ID | aaepl.pantnagar@sangkaj.com |
| MD Email ID | steel@sangkaj.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1565
|
0
|
0
|
1008
|
1890
|
4463
|
| Check Qty |
1565
|
0
|
0
|
1008
|
1890
|
4463
|
| NG Qty |
25
|
0
|
0
|
12
|
7
|
44
|
| Scrap | 0 |
| Rework | 44 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All WIP 100% Rechecked |
3. Process Flow
| Process Flow Description |
|---|
| CNC Blank Inward---Hobbing ---HT--- ID Honing---Teeth Honing -----Final Inspection ----Oiling Packing ---Dispatch |
4. Process Details
| Process / Operation | Teeth Honing |
| Outsource | Yes |
| Machine / Cell | Teeth Honing Machine |
| Machine / Cell No. | HMX 260 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Less Allowance for teeth Honing | Less allowance for teeth honing | 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 | Patch mark on teeth |
| Why 2 | less material removal on teeth honing operation |
| Why 3 | As per process requirement no sufficient stock for teeth honing |
| Why 4 | Teeth honing input material face runout excess due to part excess bend in HT process |
| Why 5 | HT charge making fixture bend & Crack |
| Root Cause (Occurance) | HT charge making fixture bend & Crack |
Root Cause Analysis (Outflow)
| Why 1 | Patch mark on teeth |
| Why 2 | Part detected in final inspection |
| Why 3 | less awareness of final inspector |
| Why 4 | N/A |
| Why 5 | N/A |
| Root Cause (Outflow) | Less awareness of final inspector |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | New HT charge making plate ordered | Mr.Raut | 20/03/2024 | Pending |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 1) Training provided to all final inspector 2) Ok Not Ok part OPL displayed at final inspection 3) Before teeth honing 100% face runout inspection started . |
| 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) |
Evidence attached 684_Occurance_Before.xlsx |
| Occurance (After) |
Evidence attached 684_Occurance_After.xlsx |
| Outflow (Before) |
Evidence attached 684_Outflow_Before.xlsx |
| Outflow (After) |
Evidence attached 684_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | N/A |
12. Document Review
| Documents | ControlPlan, WISOP, AuditCheckSheet, InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |