QFR No - 8000874503
Defect Details
| NC No. | 8000874503 |
| NC Date | 16/05/2024 |
| NC Submission Date | |
| Part No. | F2PH01302B |
| Part Name | VALVE RETAINER (K-1015) |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-ID UNDERSIZE (BURR REVOLVED) |
1. Problem Description
| Defect Description | ID undersize |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 10 |
| Is Defect Repeatative? | No |
| 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 |
1200
|
0
|
0
|
1500
|
0
|
2700
|
| Check Qty |
1200
|
0
|
0
|
1500
|
0
|
2700
|
| NG Qty |
10
|
0
|
0
|
3
|
0
|
13
|
| Scrap | 10 |
| Rework | 3 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Suspected material Segregation at Customer End |
3. Process Flow
| Process Flow Description |
|---|
| RM Inward at MI K-11- Store at Janki Engineering - Parting on Traub machine - Chamfer on Drill machine - Inward Inspection at k-11-Counter Boring on CNC Machine - Plating Green Passivation - Final Inspection - Dispatch |
4. Process Details
| Process / Operation | Counter Boring on CNC |
| Outsource | No |
| Machine / Cell | CNC Cell |
| Machine / Cell No. | CNC-02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled operator | As per skilled matrix chart skilled operator | O |
| Tool | Wrong Insert Use For Facing Operation | Correct Insert TNMGG04 use for Facing operation | O |
| Method | Wrong Inspection Instruments | Plain PPG use Instead of step gauge on CNC Machien | X |
| Material | Hard Material | Material Hardness Found 78-82 HRB | O |
| Machine | During Counter facing Operation Facing tool over feed | During Counter Facing operation Feed obs. 0.15mm/Rev. Instead of 0.12mm/Rev. | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5Nos/Hr |
7. Root Cause Analysis (Occurance)
| Why 1 | Not as per specification -ID Undersize Burr fold At ID |
| Why 2 | Feed Over During Valve Retainer Job Change Over. |
| Why 3 | During Job Change Over Valve Retainer facing tool Process Parameters Not Correction in program on CNC machine. |
| Why 4 | During Counter Operation Process Facing Tool Over Feed of Facing Tool on CNC Machine. |
| Why 5 | |
| Root Cause (Occurance) | During Counter Operation Process Facing Tool Over Feed of Facing Tool on CNC Machine. |
Root Cause Analysis (Outflow)
| Why 1 | Not as per specification -ID Undersize Burr fold At ID |
| Why 2 | Counter ID Fold Burr not detect on final inspection |
| Why 3 | ID Inspection By Plain PPG |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | ID Inspection By Plain PPG |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Counter Facing tool process parameter Feed Reduce -0.12mm/rev. Instead of 0.15mm/rev | Production Head / Quality Head | 20/05/2024 | 21/05/2024 | Completed |
| Outflow | New Step Gauge Provide on CNC Machine and Final Inspection Stage | Quality Head | 20/05/2024 | 30/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Step Gauge Provide On CNC Machine |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
During Counter Operation Process Facing Tool Over Feed of Facing Tool on CNC Machine. 808_Occurance_Before.jpg |
| Occurance (After) |
Counter Facing tool process parameter Feed Reduce -0.12mm/rev. Instead of 0.15mm/rev 808_Occurance_After.jpg |
| Outflow (Before) |
Required Special Gauge Not Available For Both Counter ID at time Inspection. 808_Outflow_Before.jpg |
| Outflow (After) |
New Step Gauge Provide on CNC Machine and Final Inspection Stage 808_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Valve Retainer Family |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | OK |