QFR No - 8000877855
Defect Details
| NC No. | 8000877855 |
| NC Date | 11/06/2024 |
| NC Submission Date | |
| Part No. | 520BZ00102 |
| Part Name | CAP OIL LOCK-LML |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-ID STEP |
1. Problem Description
| Defect Description | ID step |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 56 |
| 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 |
730
|
0
|
0
|
0
|
1460
|
2190
|
| Check Qty |
730
|
0
|
0
|
0
|
1460
|
2190
|
| NG Qty |
56
|
0
|
0
|
0
|
0
|
56
|
| Scrap | 56 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Suspected Material Segregation at customer End . |
3. Process Flow
| Process Flow Description |
|---|
| RM Inward - store- Traub Parting and boring - Bottom side chamfer- CNC Turning and Boring - OD Grinding- Plating- Final Inspection - Dispatch |
4. Process Details
| Process / Operation | CNC Turning and Boring |
| Outsource | No |
| Machine / Cell | CNC Section |
| Machine / Cell No. | CNC nO-2 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Wrong Tool Use | Boring Shank dia 8mmTool Use On CNC Machine . | X |
| Method | Inspection Wrong | 10nos Per Bin ID Visual On Final Inspection Stage . | X |
| Man | Man Unskilled | As Per Skilled Matrix Operator is Skill | O |
| Material | Hard Material | Hardness 75-78 HRB | O |
| Machine | Machine Condition Not OK | As per PM schedule Machine Condition is OK | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10nos/Bin |
7. Root Cause Analysis (Occurance)
| Why 1 | NOT AS PER SPECIFICATION-ID STEP |
| Why 2 | ID STEP Defect Observed On CNC machine |
| Why 3 | Tool Vibration During Boring Operation On CNC |
| Why 4 | Boring tool Shank was Weak on CNC machine . |
| Why 5 | |
| Root Cause (Occurance) | Boring tool Shank was Weak on CNC machine . |
Root Cause Analysis (Outflow)
| Why 1 | NOT AS PER SPECIFICATION-ID STEP |
| Why 2 | Final Inspection Stage ID Visual Sampling Frequency Very Low |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Final Inspection Stage ID Visual Sampling Frequency Very Low |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | ID Visual Sampling Increase 50Nos/Bin Instead of 5Nos | Quality Head | 13/06/2024 | 14/06/2024 | Completed |
| Occurance | Boring Tool Replace Shank dia Kept 11mm Instead of 8mm. | Production Head | 13/06/2024 | 15/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | ID Visual Inspection Frequency Change 50Nos /bin Instead of 5nos. |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 50Nos/Bin |
10. Evidance of Countermeasure
| Occurance (Before) |
Boring tool Shank was Weak on CNC machine . 855_Occurance_Before.docx |
| Occurance (After) |
Boring Tool Replace Shank dia Kept 11mm Instead of 8mm. 855_Occurance_After.docx |
| Outflow (Before) |
Final Inspection Stage ID Visual Sampling Frequency Very Low 855_Outflow_Before.jpg |
| Outflow (After) |
ID Visual Sampling Increase 50Nos/Bin Instead of 5Nos 855_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Cap Models |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | Nil |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | OK |