QFR No - 8000876571
Defect Details
| NC No. | 8000876571 |
| NC Date | 30/05/2024 |
| NC Submission Date | |
| Part No. | 165FG01101 |
| Part Name | GEAR PRIMARY ASSLY 3W-4S 200 cc LPG |
| Supplier Name & Code | 100237-SANJEEV AUTO PARTS MRFS PVT LT |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | MIX UP OTHER MODEL-WRONG HOBBING ISSUE (77TEETH) |
1. Problem Description
| Defect Description | Wrong teeth Hobbing done (77 teeth Hobbing done instead of 74 Nos) |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | vpwankhade@sanjeevgroup.com |
| Plant Head/CEO Email ID | rmtiwari@sanjeevgroup.com |
| MD Email ID | maithilee@sanjeevgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
200
|
0
|
0
|
210
|
240
|
650
|
| Check Qty |
200
|
0
|
0
|
210
|
240
|
650
|
| NG Qty |
0
|
0
|
0
|
0
|
0
|
0
|
| Scrap | 0 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% material checked at WIP &Final inspection confirmation with tick mark identification to ensure defect free parts. |
3. Process Flow
| Process Flow Description |
|---|
| Raw Material Inward Bar Cutting Billet Heating Hot Forging Normalizing Shotblasting Coining Preturning Peircing-1 Peircing-2 Shaving-1 Shaving-2 Milling-1 Milling-2 Finish turning 1st setup Finish turning 2nd setup Finish turning 3rd setup Deburring Final Inspection CNC Blank Inward Inspection CNC Blank Traciability Marking Hobbing Teeth Chamfering Gear Shaving Heat tratment Shotblasting ID Turning Bush Pressing Bush Turning Washing Final inspection |
4. Process Details
| Process / Operation | Hobbing |
| Outsource | No |
| Machine / Cell | GPH Cell |
| Machine / Cell No. | Glesson -1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | material mixup with GPH single groove in GPH double groove | During hobbing part loading visaul inspection to be done. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | MIX UP OTHER MODEL-WRONG HOBBING ISSUE (77 TEETH) |
| Why 2 | WRONG CNC BLANKLOADED FOR HOBBING |
| Why 3 | VERIFICATION OF BLANK NOT DONE BEFORE LOADING FOR HOBBING |
| Why 4 | VERIFICATION (INPECTION) SKIPPED |
| Why 5 | NA |
| Root Cause (Occurance) | VERIFICATION (INPECTION) SKIPPED |
Root Cause Analysis (Outflow)
| Why 1 | MIX UP OTHER MODEL-WRONG HOBBING ISSUE (77 TEETH) |
| Why 2 | Not arrested during DFCE inspection |
| Why 3 | Dail pressure scale value inspection skipped during DFCE Inspection. |
| Why 4 | NA |
| Why 5 | NA |
| Root Cause (Outflow) | Dail pressure scale value inspection skipped during DFCE Inspection. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | OPL DISPLAYED AT HOBBING | VGW | 04/06/2024 | 04/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Visual Inspection |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Wrong part loaded during hobbing verification skipped 831_Occurance_Before.pdf |
| Occurance (After) |
Q-Alert dispayed at hobbing sytage for identification of CNC parts. 831_Occurance_After.pdf |
| Outflow (Before) |
Dial pressure scale value inspection skipped durong inspection 831_Outflow_Before.pdf |
| Outflow (After) |
Q-Alert dispayed at Final inspection stage for inspection of dial pressure scale value 831_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | ALL GPH Family |
12. Document Review
| Documents | |
| Specify Other Document | Q-Alert Dispalyed |
13. Effectiveness Of Action
| Reviewed Quantity | 2000 |
| Reason for submission | Repeated Quality issue -POKA YOKE required in Machine (Possibility of customer Complaint) Also outflow action missing |