QFR No - 8000868408
Defect Details
| NC No. | 8000868408 |
| NC Date | 22/03/2024 |
| NC Submission Date | |
| Part No. | F2BZ05712B |
| Part Name | CAP OIL LOCK - J1D FF (10mm taper) |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-PARELLELISM MORE |
1. Problem Description
| Defect Description | Parallelism more |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 42 |
| 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 |
3500
|
0
|
0
|
1750
|
0
|
5250
|
| Check Qty |
3500
|
0
|
0
|
1750
|
0
|
5250
|
| NG Qty |
42
|
0
|
0
|
5
|
0
|
47
|
| Scrap | 47 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All suspected FG Material Segregation at customer end and Final Inspection Area . |
3. Process Flow
| Process Flow Description |
|---|
| Raw material Inward - Raw Material store -Parting on Traub machine -Bottom side ID(10.5)chamfer-OD Grinding -Semi Finish Inward - CNC ID Boring, Taper (10°)Turing, Facing -Plating Green)- Final inspection- Packing- Dispatch . |
4. Process Details
| Process / Operation | Parting on Traub machine -Face uneven |
| Outsource | Yes |
| Machine / Cell | Traub(A-25)-02 |
| Machine / Cell No. | Traub Section |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Parting on Traub machine -Face uneven | Bottom side Ring Chatter marks | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 20pc/Bin |
7. Root Cause Analysis (Occurance)
| Why 1 | Parallelism More |
| Why 2 | Chatter marks On bottom side |
| Why 3 | Bottom Side Face Operation Finish On Traub Machine. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Bottom Side Face Operation Finish On Traub Machine |
Root Cause Analysis (Outflow)
| Why 1 | Parallelism More |
| Why 2 | Parallelism Not 100% Inspection after CNC Machining |
| Why 3 | Dial Test Indicator Instrument Not Available on CNC machine. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Dial Test Indicator Instrument Not Available on CNC machine. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Dial Test Indicator Instrument Arrange on CNC machine. | quality Head | 24/03/2024 | 24/03/2024 | Completed |
| Outflow | Work Instruction Display on Defected Material Handling | Quality Head | 22/04/2024 | 22/03/2024 | Completed |
| Occurance | Process add of Bottom facing on CNC Machine | Quality Head | 22/03/2024 | 22/03/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Parallelism Parameter Check On CNC machine |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Parting ,bottom Side Chamfer (0.8x45°) and Facing Process on Traub Machine. 721_Occurance_Before.pptx |
| Occurance (After) |
CNC Process add-Chamfer(0.8X45°) and bottom side facing process. After Traub Parting. 721_Occurance_After.pptx |
| Outflow (Before) |
Sample Basis (10-15Nos/Hr) Parallelism Verification On CNC Machine. 721_Outflow_Before.pptx |
| Outflow (After) |
1)Parallelism parameter 100% Verification By Comparator Stand On CNC Machine. 2) OJT For Comparator Handling to CNC Operator 721_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Only For Cap oil lock J1D Model |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, ProcessFlowChart |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 180 |
| Reason for submission | OK |