QFR No - 8000883655
Defect Details
| NC No. | 8000883655 |
| NC Date | 22/07/2024 |
| NC Submission Date | |
| Part No. | B2BK02403O |
| Part Name | CALIPER BODY-RAW K2 REAR (MODEL-B20013) |
| Supplier Name & Code | 101180-MAULI CAST TECH PVT. LTD |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | BLOW HOLES-BH,PH, DENT & DAMAGEDON A CLASS AREA |
1. Problem Description
| Defect Description | BLOW HOLES-BH,PH, DENT & DAMAGEDON A CLASS AREA |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 138 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@maulicasttech.com |
| Plant Head/CEO Email ID | planthead@maulicasttech.com |
| MD Email ID | shrikant.shelke@maulimetal.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
7101
|
0
|
0
|
336
|
1724
|
9161
|
| Check Qty |
7101
|
0
|
0
|
336
|
1724
|
9161
|
| NG Qty |
138
|
0
|
0
|
6
|
32
|
176
|
| Scrap | 7 |
| Rework | 31 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All remaining parts are being segregated at customer end. And in-house FG also all parts are rechecked & confirmed OK before dispatch. |
3. Process Flow
| Process Flow Description |
|---|
| 1.Raw material received-->2.Incoming Inspection-->3.Storage-->4.Ingot Melting-->5.N2 Degassing Process-->6.Transfer to GDC Production-->7.Decoring-->8.Gate/Raiser Cutting-->9.Buffing-->10.Fettling-->11.Heat Treatment-->12.Shot Blasting--> 13.Engraving/Marking-->14.Final Inspection-->15.Packing & Move to FG-->16.PDIR Inspection-->17.Dispatch. |
4. Process Details
| Process / Operation | At Post operation stage during cutting & fetlling. |
| Outsource | No |
| Machine / Cell | N/A |
| Machine / Cell No. | N/A |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Semi skilled manpower, Less awareness about part handling process. | Operator has changed,Less awareness of part handling process. | X |
| Tool | Use of improper tool. | Not using standard tools. | X |
| Method | Metal to metal contact,Using non-standard bins, shortage of bins. | Part to part contact found,No standard bins for part handling,No sufficient bins for part movement. | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | Every lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Metal to metal contact during every operation. |
| Why 2 | Due to not using standard bins. |
| Why 3 | Due to some bins are got damaged. |
| Why 4 | Due to put over load in bins. |
| Why 5 | Due to lack of standard bins. |
| Root Cause (Occurance) | Due to lack of standard & dedicated bins for part handling in every process. And operators are semi skilled. |
Root Cause Analysis (Outflow)
| Why 1 | Avoid metal to metal contact during every operation. |
| Why 2 | To be use standard bins for part handling. |
| Why 3 | Don`t to be use damaged bins for carrying the parts. |
| Why 4 | Put the parts in bins as per defined qty. |
| Why 5 | To procure standard bins for proper part handling. |
| Root Cause (Outflow) | Need to procure standard bins for every process & operations. And OJT need to provide all semi skilled operators. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Now procured standard bins for part handling. And training has given to semi skilled operators. | Mr.Somesh Rout & Debanand Mohapatra | 14/08/2024 | Completed | |
| Outflow | Standard bins are provided for part handling & operators training | Mr.Somesh Rout & Debanand Mohapatra | 14/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Q gate inspection activity has started before heat treatment process. |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | Every lot |
10. Evidance of Countermeasure
| Occurance (Before) |
No standard & dedicated bins are there at post operation stage for part handling process. 961_Occurance_Before.jpeg |
| Occurance (After) |
Now standard & dedicated bins are procured for part handling. 961_Occurance_After.jpeg |
| Outflow (Before) |
Operators are not fully aware about the customer requirement. 961_Outflow_Before.jpeg |
| Outflow (After) |
Now provided training & awareness to operators about customer requirement. 961_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applicable to all rear caliper model family. |
12. Document Review
| Documents | WISOP, AuditCheckSheet, ProcessFlowChart, PackingStd, InspCheckSheet |
| Specify Other Document | N/A |
13. Effectiveness Of Action
| Reviewed Quantity | 300 |
| Reason for submission | Material handling improved. |