QFR No - 8000881358
Defect Details
| NC No. | 8000881358 |
| NC Date | 05/07/2024 |
| NC Submission Date | |
| Part No. | B2RC03824O |
| Part Name | CALIPER PISTON ANODISED DIA 28 |
| Supplier Name & Code | 101261-BHOGALE AUTOMOTIVE PRIVATE LIM |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | SURFACE FINISH NOT OK-UNCLEAN AT BOTTOM |
1. Problem Description
| Defect Description | Unclean AT Bottom Side |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 23 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | nikhil.kulkarni@bhogaleauto.com |
| Plant Head/CEO Email ID | rajendra.randive@bhogaleauto.com |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
0
|
0
|
1300
|
900
|
3200
|
| Check Qty |
1000
|
0
|
0
|
1300
|
900
|
3200
|
| NG Qty |
23
|
0
|
0
|
0
|
0
|
23
|
| Scrap | 23 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1) 2300 parts verified in pipeline. 2) 2nd firewall implemented till issue resolved. |
3. Process Flow
| Process Flow Description |
|---|
| Reciept insp. > Forging > Heat treatment > Trimming > Grinding > Final Inspection > Packing and dispatch |
4. Process Details
| Process / Operation | Forging |
| Outsource | No |
| Machine / Cell | Forging press |
| Machine / Cell No. | P1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Die not cleaned | Forging lubrication paste diposited on die in running | O |
| Machine | Pressure variation | Checked consistancy over 100 parts, found ok | X |
| Material | Short input billet size | Billet cutting is program controlled and checked repeatability found ok | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Manual/ Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 10 |
7. Root Cause Analysis (Occurance)
| Why 1 | After CNC machining 2nd, part having unclean face. |
| Why 2 | Machining not done on partial outer portion of face. |
| Why 3 | Forging face is not having flatness, as required. |
| Why 4 | Forging ejection pin having lubrication paste stuck on corners. |
| Why 5 | Die and pin does not cleaned, during production. |
| Root Cause (Occurance) | Tooling not cleaned frequently during production. |
Root Cause Analysis (Outflow)
| Why 1 | Defect skipped from visual inspection. |
| Why 2 | Due to surface dying, surface appearance matches with machining |
| Why 3 | Difference difficult to understand |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspector not understand the defect |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Tool cleaning after every 500 nos forging is implemented in WIS | NSK | 28/06/2024 | Pending | |
| Occurance | Control plan revised | NSK | 28/06/2024 | Pending | |
| Outflow | Refreshment training given to inspectors. | NSK | 27/06/2024 | Pending |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No change in inspection method |
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | all |
10. Evidance of Countermeasure
| Occurance (Before) |
No tool cleaning frequency defined in forging WIS 907_Occurance_Before.png |
| Occurance (After) |
Cleaning frequency defined in forging WIS 907_Occurance_After.png |
| Outflow (Before) |
Defect forging unclean not in visual inspection WIS 907_Outflow_Before.pdf |
| Outflow (After) |
Defect forging unclean added in visual inspection WIS 907_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Not applicable |
12. Document Review
| Documents | ControlPlan, WISOP |
| Specify Other Document | Not applicable |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |