QFR No - 8000878522
Defect Details
| NC No. | 8000878522 |
| NC Date | 15/06/2024 |
| NC Submission Date | |
| Part No. | 520HL00202 |
| Part Name | OIL LOCK COLLAR |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | DIAMETER OVER SIZE-OD OVER SIZE |
1. Problem Description
| Defect Description | OIL LOCK COLLAR OD MORE ISSUE |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 635 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | bhpnhqxb2aqiqeo31315nure.gif |
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 |
4800
|
3200
|
0
|
0
|
0
|
8000
|
| Check Qty |
4800
|
3200
|
0
|
0
|
0
|
8000
|
| NG Qty |
635
|
0
|
0
|
0
|
0
|
635
|
| Scrap | 0 |
| Rework | 635 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Suspected Material Segregation at customer End . |
3. Process Flow
| Process Flow Description |
|---|
| Rm Inward- store- Parting on Traub Machine - ID Chamfer - OD Grinding - Plating - Final Inspection- Dispatch |
4. Process Details
| Process / Operation | OD Grinding - |
| Outsource | No |
| Machine / Cell | Centerless Grinding |
| Machine / Cell No. | CLG-7 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Hard Material | Hardness observed 78-84 HRB | X |
| Tool | Wrong Grade Grinding Wheel Use | The control wheel and grinding wheel were of the correct grade and size. | X |
| Man | Unskilled Centerless Grinding Operator. | New Operator | O |
| Machine | Machine Condition Not Ok | The control wheel slide locking screw is not properly locking. | O |
| Method | Machining Process and Inspection Method Wrong. | "The OD grinding process method and inspection method are acceptable | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | DIAMETER OVER SIZE-OD OVER SIZE |
| Why 2 | After dressing the control wheel, the operator did not properly tighten the slide |
| Why 3 | The control wheel slide locking screw thread is worn. |
| Why 4 | The operator is not aware of the side effects of the sliding locking screw |
| Why 5 | New operator. |
| Root Cause (Occurance) | The control wheel slide locking screw thread is worn. |
Root Cause Analysis (Outflow)
| Why 1 | DIAMETER OVER SIZE-OD OVER SIZE |
| Why 2 | Defected parts Not Detect On Final inspection Stage. |
| Why 3 | New Final Inspector |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | New Final Inspector |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Centerless Grinding Machine maintenance was done as per the PM schedule | Production And maintenance head | 18/06/2024 | 18/06/2024 | Completed |
| Outflow | Training for the operator and work instructions are displayed on the CLG machine. | Quality Head | 19/06/2024 | 19/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | An additional snap gauge is provided on the CLG grinding machine. |
| 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) |
The control wheel slide locking screw thread is worn. 872_Occurance_Before.docx |
| Occurance (After) |
Centerless Grinding Machine maintenance was done as per the PM schedule 872_Occurance_After.docx |
| Outflow (Before) |
New Final Inspector r 872_Outflow_Before.docx |
| Outflow (After) |
Training for the operator and work instructions are displayed on the CLG machine. 872_Outflow_After.docx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Oil Lock Collar |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | OJT |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | Reviewed next two lots found ok |