QFR No - 8000877854
Defect Details
| NC No. | 8000877854 |
| NC Date | 11/06/2024 |
| NC Submission Date | |
| Part No. | 550BZ01402 |
| Part Name | CAP OIL LOCK - DF01 |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-ID OUT |
1. Problem Description
| Defect Description | ID wall thickness variation |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| 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
|
0
|
1280
|
1960
|
| Check Qty |
680
|
0
|
0
|
0
|
1280
|
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 & Pilot Drill -Bottom side chamfer-CNC-ID boring and Turning -OD Grinding -Plating- Final Inspection-Dispatch. |
4. Process Details
| Process / Operation | Parting & Pilot Drill |
| Outsource | Yes |
| Machine / Cell | Traub M/C |
| Machine / Cell No. | Traub No.2 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Wrong tool use for Pilot drill | Yes , Long length Drill Use For pilot drill operation on Traub machine | X |
| Man | Unskilled operator | Skilled Operator On Traub Machine | O |
| Method | Parting & Pilot Drill Process wrong and Gauge Not Available. | Parting Process on Traub Machine But Concentricity Gauge Not Available On CNC Machine. | X |
| Material | Wrong grade &Hard Material use | Material Grade-EN1A and Hardness -87HRB | O |
| Machine | Machine Condition Not Ok | As per PM Check sheet Traub Machine Condition had 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 | 20 NOS |
7. Root Cause Analysis (Occurance)
| Why 1 | NOT AS PER SPECIFICATION-ID OUT |
| Why 2 | Concentricity Problem observed During Piolet Drilling Process on Traub Machine. |
| Why 3 | Piolet Drill Vibrate On Traub Machine during Piolet Drill Operation |
| Why 4 | Piolet Drill had Over length Than Required . |
| Why 5 | |
| Root Cause (Occurance) | Piolet Drill had Over length Than Required |
Root Cause Analysis (Outflow)
| Why 1 | NOT AS PER SPECIFICATION-ID OUT |
| Why 2 | Sample Basis and Visual Inspection On CNC Machine. |
| Why 3 | Concentricity Gauge not Available On CNC machine. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Concentricity Gauge not Available On CNC machine. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Piolet Drill Replace as per Required Length | Traub Operator / Line Inspector | 13/06/2024 | 13/06/2024 | Completed |
| Outflow | Concentricity Gauge Provide On CNC Machine. | QA Incharge. | 22/06/2024 | 22/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Concentricity Parameter 100% Verifying on CNC Machine. |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 20nos / Hr |
10. Evidance of Countermeasure
| Occurance (Before) |
Piolet Drill had Over length Than Required 854_Occurance_Before.jpg |
| Occurance (After) |
Piolet Drill Replace as per Required Length 854_Occurance_After.docx |
| Outflow (Before) |
Concentricity Gauge not Available On CNC machine. 854_Outflow_Before.jpg |
| Outflow (After) |
Concentricity Gauge Provide On CNC Machine. 854_Outflow_After.docx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Cap OIL locks Family |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | OK |