QFR No - 8000884338
Defect Details
| NC No. | 8000884338 |
| NC Date | 26/07/2024 |
| NC Submission Date | |
| Part No. | 520HL00202 |
| Part Name | OIL LOCK COLLAR |
| Supplier Name & Code | 100176-GKN SINTER METALS PRIVATE LIMI |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-CRACK |
1. Problem Description
| Defect Description | Crack |
| Detection Stage | Inprocess |
| Problem Severity | Safety |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | Rajendra.Sethiya@gknpm.com |
| Plant Head/CEO Email ID | Pratik.Dharangaonkar@gknpm.com |
| MD Email ID | Rajesh.Mirani@gknpm.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
7642
|
8000
|
0
|
0
|
0
|
15642
|
| Check Qty |
7642
|
8000
|
0
|
0
|
0
|
15642
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Quality Alert raised at In process area. Awareness training given to all concerned stakeholders . All stock is under hold for verification |
3. Process Flow
| Process Flow Description |
|---|
| Mixing-Forming-Sintering-steam treatment -PDI to Post FG |
4. Process Details
| Process / Operation | Forming |
| Outsource | No |
| Machine / Cell | Small Segemnt |
| Machine / Cell No. | Plant 1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | New Opeartor | Operator Skill Matrix verified | O |
| Method | Part fallen on Rotary table due to conveyor height Mismatch | Past History of Concerned batch verified observed Excess gap creating Impact on OD | X |
| Material | Wrong Mix | MTR | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Sampling Inspection |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | Crack Generated on OD During forming process |
| Why 2 | Impact Generated on Part OD on Rotary table during TRansferring From conveyor |
| Why 3 | Excess gap between rotary table & conveyor chute End |
| Why 4 | No checkpoint to verify gap |
| Why 5 | |
| Root Cause (Occurance) | Excess gap between Rotary table & Conveyor chute end resulted into excess impact on Part OD |
Root Cause Analysis (Outflow)
| Why 1 | Crack parts outflown to ETL |
| Why 2 | Crack parts not detected during Inspection |
| Why 3 | Inspection frequency not adequate |
| Why 4 | Inspection done on sampling basis |
| Why 5 | |
| Root Cause (Outflow) | Inspection done on sampling basis |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Glide path provided between Rotary table & Conveyor Clearence to avoid impact | Rohan G | 30/07/2024 | 30/07/2024 | Completed |
| Outflow | Inspection Frequency revised from 5 Parts/4 hour to 5 Parts/ 1hour | Rohan G | 30/07/2024 | 30/07/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection Frequency revised from 5 Parts/8 hour to 5 parts/ 1 hour |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10 Nos |
10. Evidance of Countermeasure
| Occurance (Before) |
Excess gap on Rotary table 978_Occurance_Before.pptx |
| Occurance (After) |
Gap eliminated to avoid stuck up issue 978_Occurance_After.pptx |
| Outflow (Before) |
Before Inspection frequency 5 Parts/8 hour 978_Outflow_Before.pdf |
| Outflow (After) |
After Inspection Frequency 5 Parts/ 1 Hour 978_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | OK |