QFR No - 8000877871
Defect Details
| NC No. | 8000877871 |
| NC Date | 11/06/2024 |
| NC Submission Date | |
| Part No. | 520HL00202 |
| Part Name | OIL LOCK COLLAR |
| Supplier Name & Code | 100176-GKN SINTER METALS PRIVATE LIMI |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-CRACK - MATERIAL DEFECT |
1. Problem Description
| Defect Description | CUT MAK |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 5 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | nitin.palve@gknpm.com |
| Plant Head/CEO Email ID | Deepak.jadhav@gknpm.com |
| MD Email ID | Rajesh.Mirani@gknpm.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
14000
|
28000
|
0
|
0
|
0
|
42000
|
| Check Qty |
14000
|
28000
|
0
|
0
|
0
|
42000
|
| NG Qty |
7000
|
12
|
0
|
0
|
0
|
7012
|
| Scrap | 7000 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Quality Alert raised at In process area. Awareness training given to all concern stakeholders. All stock is under |
3. Process Flow
| Process Flow Description |
|---|
| Mixing-Forming-Sintering- Barreling- Steam treatment PDI |
4. Process Details
| Process / Operation | Forming |
| Outsource | No |
| Machine / Cell | Smal segment |
| Machine / Cell No. | Plant 1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | New Operator | Operator Skill Matrix verified | O |
| Method | Parts fallen in rotary table due to conveyer height mismatch | Past history of concerned batch verified & Observed Excess gap creating impact on OD | X |
| Material | Wrong Mix | MTR | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Sampling Inspection |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | Crack Generated on OD During Forming Process |
| Why 2 | Impact generated on part OD on Rotary table during transferring from conveyor |
| Why 3 | Excess gap between Rotary table & Conveyor Chute end |
| Why 4 | No Checkpoint to verify gap |
| Why 5 | |
| Root Cause (Occurance) | Excess gap between Rotary table & Conveyor Chute end resulted into excess impact on part OD |
Root Cause Analysis (Outflow)
| Why 1 | Crack Parts outflown to ETL |
| Why 2 | Crack parts not detected during Inspection |
| Why 3 | Inspection Frequency not adequate |
| Why 4 | Inspection done on sampling basis |
| Why 5 | |
| Root Cause (Outflow) | Inspection done on sampling basis |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Inspection Frequency Revised from 5 Parts / 4 Hours to 5 Parts/1 Hour | Rohan G | 04/07/2024 | 22/07/2024 | Completed |
| Occurance | Glide Path Provided between Rotary table & Conveyer Clearence to avoid Impact | Rohan Gunwant | 04/07/2024 | 22/07/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection frequency Revised from 5/8 Hour to 5 Parts/1 hour |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10 Nos |
10. Evidance of Countermeasure
| Occurance (Before) |
Excess Gap on Rotary Table 857_Occurance_Before.pptx |
| Occurance (After) |
Gap Eliminated to avoid stuck up issue 857_Occurance_After.pptx |
| Outflow (Before) |
Before Inspection Frequency 5 Parts/8 Hour 857_Outflow_Before.pdf |
| Outflow (After) |
After Inspection Frequency 5 Parts/ 1 Hour 857_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | OK |