QFR No - 8000870484
Defect Details
| NC No. | 8000870484 |
| NC Date | 08/04/2024 |
| NC Submission Date | |
| Part No. | B2FP04503O |
| Part Name | HOLDER BRACKET BODY RAW- K2 REAR ABS |
| Supplier Name & Code | 101180-MAULI CAST TECH PVT. 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 | Aesthetic |
| NG Quantity | 87 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@maulicasttech.com |
| Plant Head/CEO Email ID | planthead@maulicasttech.com |
| MD Email ID | shrikant.shelke@maulimetal.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
9301
|
0
|
0
|
835
|
3080
|
13216
|
| Check Qty |
9301
|
0
|
0
|
835
|
3080
|
13216
|
| NG Qty |
87
|
0
|
0
|
9
|
33
|
129
|
| Scrap | 6 |
| Rework | 36 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All castings are segregated at ETL end & in-house also. And defective parts are being reworked at M/s-Mauli Casttech. |
3. Process Flow
| Process Flow Description |
|---|
| 1.Raw material receive-->2.Incoming Inspection-->3.Raw Ingot Melting-->4.N2 Degassing Process-->5.Liquid Metal Transfer-->6.GDC Production-->7.Gate/Raiser Cutting-->8.Buffing Process-->9.Fetlling Process-->10.Heat Treatment-->11.Shot Blasting-->12.Engraving/Marking-->13.Final Inspection-->14.Move to FG-->15.PDIR Inspection-->16.Packing & Dispatch. |
4. Process Details
| Process / Operation | At Riser & gate cutting stage. |
| Outsource | No |
| Machine / Cell | N/A |
| Machine / Cell No. | N/A |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Coating mixing process not ok. | Operator manually mixing the water & die coat. | X |
| Method | Metal to metal contact,New manpower,Impurities in molten metal | Poor material handling,Change of regular manpower,Dross in metal | X |
| Man | Unskilled manpower | New operator deputed for operation. | X |
| Tool | Improper tool using for operation | Tool shape not good. | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | 100% visual inspecti |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | Every lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Metal to metal contact in shop floor. |
| Why 2 | Poor material handling. |
| Why 3 | Bins are got damaged. |
| Why 4 | Separate bins are not available. |
| Why 5 | Plastic bin shortage for shop floor movement. |
| Root Cause (Occurance) | During shop floor movement of casting dedicated bins are not available. |
Root Cause Analysis (Outflow)
| Why 1 | No metal metal contact during operation. |
| Why 2 | Proper handling of material. |
| Why 3 | Do not use the damaged bins. |
| Why 4 | Dedicated bins to be provided to operator. |
| Why 5 | |
| Root Cause (Outflow) | For shop floor casting movement dedicated bins to be provided. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Proper dedicated bins to be provide at all operation stages. | Mr.Somesh Rout | 14/08/2024 | 08/05/2024 | Completed |
| Outflow | Part wise dedicated bins to be provide for all operations. | Mr.Somesh Rout | 14/08/2024 | 08/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Q gate inspection has started at buffing & fettlling area. |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | Every lot |
10. Evidance of Countermeasure
| Occurance (Before) |
Casting movement in non-standard bins at post operation stage. 738_Occurance_Before.jpeg |
| Occurance (After) |
Now standard bins are procure for post operation stage. for proper part handling. 738_Occurance_After.jpeg |
| Outflow (Before) |
Semi skilled operator are deputed at post operation stage. 738_Outflow_Before.jpeg |
| Outflow (After) |
Now operator OJT has given & deputed at post operation stage. And skill matrix has updated. 738_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applicable to all Holder bracket model. |
12. Document Review
| Documents | PFMEA, WISOP, AuditCheckSheet, PackingStd, InspCheckSheet |
| Specify Other Document | N/A |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | found ok |