QFR No - 8000879507
Defect Details
| NC No. | 8000879507 |
| NC Date | 22/06/2024 |
| NC Submission Date | |
| Part No. | F2PH00902B |
| Part Name | VALVE RETAINER (C101B) |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | DAMAGES-MACHINING ISSUES |
1. Problem Description
| Defect Description | valve retainer machining issue |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 4 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | i2z4kjrrzalkbmbwopa4sgmv.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 |
1200
|
0
|
0
|
0
|
9000
|
10200
|
| Check Qty |
1200
|
0
|
0
|
0
|
9000
|
10200
|
| 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 |
|---|
| RM Inward - Store- Parting on Traub Machine - CNC counter boring and facing - OD Grinding- plating-- Final Inspection - Dispatch |
4. Process Details
| Process / Operation | OD Grinding |
| Outsource | No |
| Machine / Cell | CLG-05 |
| Machine / Cell No. | Grinding Cell |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Wrong Grinding Wheel Use | As Per Store Record Ok CUMI Make Grinding Wheel Use. | O |
| Material | Hard And other grade Material Use | Hardness 75-80 HRB and as per required grade CEW-1 Material Use. | O |
| Machine | Machine Condition Not oK or RPM over | Machine Condition ok But Control Wheel RPM was 45-60 | X |
| Method | Process &Inspection Method Wrong | Process Method Ok But Inspection Method After OD Grinding visual frequency Very Low | X |
| Man | Unskilled operator | As per Skilled Matrix Operator is Skilled | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | DAMAGES-MACHINING ISSUES |
| Why 2 | Part Not Proper OD Grinding On Grinding Machine |
| Why 3 | While OD grinding process, the part gets inverted. |
| Why 4 | Control Wheel RPM was Over |
| Why 5 | |
| Root Cause (Occurance) | Control Wheel RPM was Over |
Root Cause Analysis (Outflow)
| Why 1 | DAMAGES-MACHINING ISSUES |
| Why 2 | Final Inspection stage Not Detect During Visual sampling Inspection |
| Why 3 | After OD Grinding Process & Final Inspection stage visual frequency Very Low |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | After OD Grinding Process & Final Inspection stage visual frequency Very Low . |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Sampling Frequency Increase 50nos Per 500Nos Instead Of 20/500nos& After Visual Inspection Tick Marks On OD at Final Stage. | Quality Head | 31/07/2024 | 01/08/2024 | Completed |
| Occurance | Control wheel RPM Reduce 30-45 Instead Of 45-60 | Production Head | 30/07/2024 | 01/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Sampling Frequency Increase & After Visual Inspection Tick Marks On OD at Final Stage. |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Control Wheel RPM was Over 879_Occurance_Before.docx |
| Occurance (After) |
Control wheel RPM Reduce 30-45 Instead Of 45-60 879_Occurance_After.docx |
| Outflow (Before) |
After OD Grinding Process & Final Inspection stage visual frequency Very Low 879_Outflow_Before.docx |
| Outflow (After) |
Sampling Frequency Increase 50nos Per 500Nos Instead Of 20/500nos& After Visual Inspection Tick 879_Outflow_After.docx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Valve Retainer |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | Reviewed |