QFR No - 8000881302
Defect Details
| NC No. | 8000881302 |
| NC Date | 05/07/2024 |
| NC Submission Date | |
| Part No. | B2BK05603O |
| Part Name | CALIPER BODY RAW-N-TORQ CBS |
| Supplier Name & Code | 100398-MANOJ INDUSTRIES |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | BLOW HOLES-BLOW HOLE, DENT DAMAGE |
1. Problem Description
| Defect Description | EXTRA CASTING IN PAD SPRING AREA, BH & DAMAGED |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 316 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | dlad@manojind.com |
| Plant Head/CEO Email ID | siju@manojind.com |
| MD Email ID | mgnt@manojindustrieskop.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
7646
|
300
|
0
|
0
|
1200
|
9146
|
| Check Qty |
7646
|
300
|
0
|
0
|
1200
|
9146
|
| NG Qty |
316
|
0
|
0
|
0
|
0
|
316
|
| Scrap | 316 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Sort out all pipe line material |
3. Process Flow
| Process Flow Description |
|---|
| -- |
4. Process Details
| Process / Operation | Casting production |
| Outsource | No |
| Machine / Cell | MI Tilt -9 |
| Machine / Cell No. | - |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Sand core finish rough at pad spring area | Visually verified sand core | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | EXTRA CASTING IN PAD SPRING AREA |
| Why 2 | Its sand core area,Due to sand fall casting get extra material |
| Why 3 | Sand core observed rough at profile area |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Sand core observed rough at profile area |
Root Cause Analysis (Outflow)
| Why 1 | EXTRA CASTING IN PAD SPRING AREA |
| Why 2 | Skipped by final inspection. |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Skipped by final inspection. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | For smooth & avoid extra material at pad spring area silver paint applied at sand core profile area | Siju D | 09/07/2024 | 09/07/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | After final inspection dot marking done on casting at pad spring area. |
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Sand core observed rough at pad spring area 904_Occurance_Before.pptx |
| Occurance (After) |
Silver paint applied at sand core profile area. 904_Occurance_After.pptx |
| Outflow (Before) |
Skipped by final inspection 904_Outflow_Before.pptx |
| Outflow (After) |
Q alert displayed at final inspection area 904_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | -- |
12. Document Review
| Documents | |
| Specify Other Document | -- |
13. Effectiveness Of Action
| Reviewed Quantity | 200 |
| Reason for submission | Improvement found in next lots |