QFR No - 8000886611
Defect Details
| NC No. | 8000886611 |
| NC Date | 12/08/2024 |
| NC Submission Date | |
| Part No. | F2FQ00407B |
| Part Name | HOLDER HANDLE UPPER P/C (XF-521) |
| Supplier Name & Code | 201092-PRANEEL INDUSTRIES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | B/H INSIDE BORE- BLOW HOLE |
1. Problem Description
| Defect Description | Bore ID Blow Hole |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 22 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@praneelgroup.com |
| Plant Head/CEO Email ID | praneelindustries@rediiffmail.com |
| MD Email ID | anilpatil@praneelgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1633
|
0
|
0
|
250
|
0
|
1883
|
| Check Qty |
1633
|
0
|
0
|
250
|
0
|
1883
|
| NG Qty |
22
|
0
|
0
|
10
|
0
|
32
|
| Scrap | 32 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material at ETL end and at In-house sagrigated and NG quantity rejected at ETL end and at In-house. |
3. Process Flow
| Process Flow Description |
|---|
| Raw casting inward =>Powder Coating=>Powder Coating inward=>VMC Machining=>De-burring=>Final Inspection=>Packing and Dispatch. |
4. Process Details
| Process / Operation | VMC Machining |
| Outsource | No |
| Machine / Cell | VMC Machine |
| Machine / Cell No. | VMC Cell |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Machine parameter not as per control plan | Verify the machine parameter and found Ok | O |
| Tool | Drill not as per required. | Verify the drill size and found ok. | O |
| Material | Material not as per required specification. | Verify the material report found Ok. | O |
| Man | Skilled inspector not available | Verify the skill matrix,found Ok. | O |
| Method | Inspection method not as per required. | Verify the checking method and found inadequate. | X |
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 | samp.plan |
7. Root Cause Analysis (Occurance)
| Why 1 | Blow Hole inside the bore size 8.4+0.1mm. |
| Why 2 | Rubbish metal poured in the die. |
| Why 3 | Impurities observed after degassing in the furnace. |
| Why 4 | Metal cleaning process not done properly. |
| Why 5 | |
| Root Cause (Occurance) | Metal cleaning process not done properly. |
Root Cause Analysis (Outflow)
| Why 1 | Blow Hole inside the bore size 8.4+0.1mm. |
| Why 2 | Skipped from final inspection. |
| Why 3 | No awareness about checking the blow hole inside the bore. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No awareness about checking the blow hole inside the bore. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Wire Mesh filter to be implement | Mr.Ramdas Boinale | 05/09/2024 | 11/09/2024 | Completed |
| Outflow | Awareness and Training given to inspector for checking blow hole inside the bore. | Mr.Yogesh Sonune | 19/08/2024 | 19/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Visual inspection started for Blow Hole inside the bore. |
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | samp.plan |
10. Evidance of Countermeasure
| Occurance (Before) |
No any wire mesh filter provided at the insert. 1005_Occurance_Before.pptx |
| Occurance (After) |
Wire mesh filter will be implement at the insert. 1005_Occurance_After.pptx |
| Outflow (Before) |
Before no any marking at bore 8.40+0.1mm. 1005_Outflow_Before.pptx |
| Outflow (After) |
After inspection marking started near to the bore 8.40+0.1mm and Training provided for the same. 1005_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | -- |
12. Document Review
| Documents | WISOP |
| Specify Other Document | Training record |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | OK |