QFR No - 8000870485
Defect Details
| NC No. | 8000870485 |
| NC Date | 08/04/2024 |
| NC Submission Date | |
| Part No. | 520BK01573 |
| Part Name | CALIPER BODY INTEGRAL TYPE PULSAR |
| Supplier Name & Code | 101414-G. S. ENGINEERING |
| 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 | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 600 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | bhange.shrikant@rediffmail.com |
| Plant Head/CEO Email ID | subhashmarathe45@gmail.com |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
4780
|
0
|
0
|
0
|
0
|
4780
|
| Check Qty |
4780
|
0
|
0
|
0
|
0
|
4780
|
| NG Qty |
600
|
0
|
0
|
0
|
0
|
600
|
| Scrap | 600 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation to ETL end |
3. Process Flow
| Process Flow Description |
|---|
| Raw material -- Melting -- Degassing -- Core manufacturing -- Casting manufacturing -- De-coring -- Gate cutting -- Fettling & Buffing -- Punching -- Heat Treatment -- Shot Blassting -- Finel Inspection -- Dispatch. |
4. Process Details
| Process / Operation | GDC |
| Outsource | No |
| Machine / Cell | GDC Machine |
| Machine / Cell No. | M/C No.:- 03 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Turbulence is created while pouring metal into the die | Saucer is arranged for pouring the metal so that the metal reaches all the cavities uniformly | O |
| Tool | Insufficient air vents in the die, core gas was entrapment | Adequate air vents are provided in the die so that air escapes easily | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visualy |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
7. Root Cause Analysis (Occurance)
| Why 1 | Blow hole observed in casting |
| Why 2 | core gas entrapped in casting during process |
| Why 3 | Inadequate venting to escape gas from cavity during casting |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Inadequate venting to escape gas from cavity during casting |
Root Cause Analysis (Outflow)
| Why 1 | Blow hole observed in casting |
| Why 2 | Visually not detected in casting |
| Why 3 | Open after machining process at customer end |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Open after machining process at customer end |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Training given to operator & Q gate inspector. 100% inspection before & after shot blasting | Mr. S Dhabe | 06/05/2024 | 29/04/2024 | Completed |
| Occurance | Vent to be provided in die from easy escape of gases during casting | Mr. S Marathe | 06/05/2024 | 29/04/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | in-process every hour a visual inspection by production supervisor / QA, DP test is conducted every shift ,100% visual inspection before & after shot blasting & 100% visual inspection before final dispatch. |
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Air vents depth 0.1mm .Inadequate air passing through this 739_Occurance_Before.jpg |
| Occurance (After) |
Air vents depth 0.2mm. This helps the air to escape freely 739_Occurance_After.jpg |
| Outflow (Before) |
Eye sequence chart 739_Outflow_Before.pdf |
| Outflow (After) |
Eye sequence chart is updated 739_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | GDC |
12. Document Review
| Documents | WISOP |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 200 |
| Reason for submission | No defect observed in latest lot |