QFR No - 8000863605
Defect Details
| NC No. | 8000863605 |
| NC Date | 19/02/2024 |
| NC Submission Date | |
| Part No. | 520AE00100 |
| Part Name | CORE PLATE CAL 115 |
| Supplier Name & Code | 100915-CHIRAG DIE CAST PVT LTD |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | BROKEN-CLAW BROKEN |
1. Problem Description
| Defect Description | Claw Broken Issue observed at Customer End (BAL Waluj) |
| Detection Stage | Customer End |
| Problem Severity | Function |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualityassurance@chiragdiecast.com |
| Plant Head/CEO Email ID | operationshead@chiragdiecast.com |
| MD Email ID | chirag.gupta@chiragdiecast.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
12000
|
32000
|
10000
|
0
|
5000
|
59000
|
| Check Qty |
12000
|
32000
|
10000
|
0
|
5000
|
59000
|
| NG Qty |
0
|
2
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Material Rechecked visually & 2 Nos. found NG out of 59000 Nos. |
3. Process Flow
| Process Flow Description |
|---|
| PDC, Trimming, Shot Blasting , Visual Inspection, Stress Relieving ,100% Gauging for Flatness , Packing , Transportation |
4. Process Details
| Process / Operation | High Pressure Die Casting |
| Outsource | No |
| Machine / Cell | HPDC |
| Machine / Cell No. | PDC |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Claw Broken During Transit from CDC to Aurangabad | 02 Nos. found Claw Broken at Godown Aurangabad after transit | 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 | Claw Broken observed at Customer End |
| Why 2 | Claw Broken of the Part during Transit |
| Why 3 | Bottom Part Could not bear the heavy jerk during Transit |
| Why 4 | Mis handling by Transporter |
| Why 5 | Not Proper Stacking inside the vehicle. |
| Root Cause (Occurance) | All 4 Bundles ( 125 Nos.) did not having the Corrugated sheet duly covered with bubble sheet to resist the jerk during transit . |
Root Cause Analysis (Outflow)
| Why 1 | Could not Checked by Local Representative at Godown ; Aurangabad during material transfer fro Corrugated Box to Plastic Bins |
| Why 2 | No such type issue observed at Godown. |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Visual Inspection skipped during Material Transfer from Corrugated Boxes to Plastic Bins. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | PP Box Cartons development is in process , We will send you o1 PP Box to ETL with next lot on dated 03-04-2024 | Naveen Kumar | 03/04/2024 | 17/04/2024 | Completed |
| Occurance | After Approval of PP Box , We will start supply in PP Box. | Naveen Kumar | 20/04/2024 | 17/04/2024 | Completed |
| Occurance | Modified Packaging in PP Cartons in place of Corrugated Box | Mr. Naveen Kumar & Mr. Sushil ( ETL) | 10/04/2024 | 17/04/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No Change |
| 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) |
There was no Corrugated sheet at the Top & Bottom of the Carton 685_Occurance_Before.jpeg |
| Occurance (After) |
PP Cartons development under process , Sample photo attached herewith for your review & approval 685_Occurance_After.jpg |
| Outflow (Before) |
No Inspection of the Bundles during material Transfer from PP box to Plastic Bins. 685_Outflow_Before.png |
| Outflow (After) |
100% Inspection of the Bundles ( Specially Top & Bottom Pcs of the Bundle) 685_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | 1132 |
12. Document Review
| Documents | PackingStd |
| Specify Other Document | Packing standard rev |
13. Effectiveness Of Action
| Reviewed Quantity | 20000 |
| Reason for submission | OK Material Received in PP Box |