QFR No - 8000877853
Defect Details
| NC No. | 8000877853 |
| NC Date | 11/06/2024 |
| 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-ID OPERATION MISSING |
1. Problem Description
| Defect Description | ID OPERATION MISSING |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 2 |
| 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 |
680
|
0
|
0
|
1280
|
0
|
1960
|
| Check Qty |
680
|
0
|
0
|
1280
|
0
|
1960
|
| NG Qty |
2
|
0
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Suspected Material Segregation at Customer End |
3. Process Flow
| Process Flow Description |
|---|
| R/M Inward- Store- Parting And Pilot drill - Bottom side chamfer-CNC Turning and ID Boring - OD Grinding - Plating - Final Inspection - Dispatch. |
4. Process Details
| Process / Operation | Parting and Pilot Drill on Traub machine. |
| Outsource | Yes |
| Machine / Cell | Traub machine-A-25 |
| Machine / Cell No. | Traub section. |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Hard Material | Correct Grade Material use hardness ok | O |
| Man | Unskiilled Man power | Skilled operator On CNC machine | O |
| Method | Input Material & Output Material Handling Method Wrong | Input and ok out put material kept On A table And Taper Ring Gauge Not available on CNC Machine . | X |
| Tool | Wrong Tool use For Pilot Drill | Correct Required Tool On CNC Machine | O |
| Machine | CNC Machine Condition Not OK | As PM plan Check sheet Condition found ok . | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 20nos |
7. Root Cause Analysis (Occurance)
| Why 1 | NOT AS PER SPECIFICATION-ID OPERATION MISSING |
| Why 2 | Defected Part By Mistake Mix By CNC operator |
| Why 3 | Input material and out material Kept in one Location on CNC Machine. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Input material and out material Kept one location on CNC Machine. |
Root Cause Analysis (Outflow)
| Why 1 | NOT AS PER SPECIFICATION-ID OPERATION MISSING |
| Why 2 | Taper Ring Gauge Not Available for 100% Taper Parameter Inspection on CNC Machine . |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Taper Ring Gauge Not Available for 100% Taper Parameter Inspection on CNC Machine . |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Input Material and Output material separate location Two Table Arrangement on CNC Machine . | Production Head | 13/06/2024 | 14/06/2024 | Completed |
| Occurance | Taper Ring Gauge Provide on CNC Machine For 100% Inspection. | Quality Head | 25/06/2024 | 25/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Taper & ID Inspection. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Input material and out material Kept on one Table on CNC Machine. 853_Occurance_Before.jpg |
| Occurance (After) |
Now Input Material and Output material separate -separate location Two Table Arrangement on CNC Machine . 853_Occurance_After.jpg |
| Outflow (Before) |
Taper Ring Gauge Not Available for 100% Taper Parameter Inspection on CNC Machine . 853_Outflow_Before.jpg |
| Outflow (After) |
Taper Ring Gauge Provide on CNC Machine For 100% Inspection. 853_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Cap Oil Lock |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | OK |