QFR No - 8000865191
Defect Details
| NC No. | 8000865191 |
| NC Date | 29/02/2024 |
| NC Submission Date | |
| Part No. | B2GQ04103O |
| Part Name | M/CYL RAW-K1,K1R,K2,K11TDABS PDC Ø12.7 |
| Supplier Name & Code | 100471-CASTALL TECHNOLOGIES (P) LTD |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | BLOW HOLES-PIN HOLE, BLOW HOLE DENT &DAMAGED |
1. Problem Description
| Defect Description | BLOW HOLES-PIN HOLE, BLOW HOLE DENT &DAMAGED |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 445 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qa@castalltech.com |
| Plant Head/CEO Email ID | sg@castalltech.com |
| MD Email ID | nmv@castalltech.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
0
|
0
|
0
|
2100
|
0
|
2100
|
| Check Qty |
0
|
0
|
0
|
2100
|
0
|
2100
|
| NG Qty |
0
|
0
|
0
|
2
|
0
|
2
|
| Scrap | 0 |
| Rework | 2 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% checked at vendors site |
3. Process Flow
| Process Flow Description |
|---|
| Operation # 100 & 110 |
4. Process Details
| Process / Operation | PDC |
| Outsource | No |
| Machine / Cell | PDC 400 |
| Machine / Cell No. | PDC 4 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Air entrapped in cavity | verified | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 2nos/1hr |
7. Root Cause Analysis (Occurance)
| Why 1 | Air not escaped from cavity |
| Why 2 | In sufficient air vent |
| Why 3 | Air entraped in cavity |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Air entraped in cavity |
Root Cause Analysis (Outflow)
| Why 1 | Machining process at customer end |
| Why 2 | sampling inspection at castall |
| Why 3 | Blow holes will find after machining at customer end |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Blow holes will find after machining at customer end |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Cut section was added along with Sampling inspection | QA | 31/03/2024 | 04/04/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Cut section was added along with Sampling inspection |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 2nos/hour |
10. Evidance of Countermeasure
| Occurance (Before) |
Single chillvent passage available. 701_Occurance_Before.jpg |
| Occurance (After) |
Extra chillvent passage was added to reduce blow holes. 701_Occurance_After.jpg |
| Outflow (Before) |
Boroscope inspection done for bore porosity/blow holes . 701_Outflow_Before.jpeg |
| Outflow (After) |
Cut section was added Along with Boroscope inspection for porosity/blow holes . 701_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All master cylinder variants |
12. Document Review
| Documents | WISOP |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 250 |
| Reason for submission | Improvement found in next lots |