QFR No - 8000887715
Defect Details
| NC No. | 8000887715 |
| NC Date | 20/08/2024 |
| NC Submission Date | |
| Part No. | 52GQ01013O |
| Part Name | M/CYL BODY PDC BORE BURNISHED -K11,K2, |
| Supplier Name & Code | 101100-CAST 4 ALUMINIUM PVT LTD |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | BLOW HOLES-BH AFTER MACHINING |
1. Problem Description
| Defect Description | BLOW HOLES-BH AFTER MACHINING |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 58 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | info@cast4aluminium.com |
| Plant Head/CEO Email ID | info@cast4aluminium.com |
| MD Email ID | kiran@cast4aluminium.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
0
|
0
|
0
|
456
|
1456
|
| Check Qty |
1000
|
0
|
0
|
0
|
456
|
1456
|
| NG Qty |
695
|
0
|
0
|
0
|
103
|
798
|
| Scrap | 695 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Not ok parts rejected and scrapped. |
3. Process Flow
| Process Flow Description |
|---|
| RM inward & inspection -- melting -- N2 degassing -- PDC -- gate cutting -- inspection -- fettling -- shot blasting -- inspection -- packing & dispatch |
4. Process Details
| Process / Operation | PDC |
| Outsource | No |
| Machine / Cell | PDC machine |
| Machine / Cell No. | PDC machine no. 8 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Material cleaning freq. not adequate | no | O |
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 | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Blow hole observed in bore of master cylinder. |
| Why 2 | Impurities observed in material. |
| Why 3 | material cleaning freq. was decided but not effective. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | material cleaning freq. was decided but not effective. |
Root Cause Analysis (Outflow)
| Why 1 | Blow hole observed in bore of master cylinder. |
| Why 2 | New inspector was working on boroscope inspection. |
| Why 3 | Understanding of defects was less in inspector. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Understanding of defects was less in inspector. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Material cleaning freq. revised i.e. thrice in a shift. | Mubarak | 27/08/2024 | 27/08/2024 | Completed |
| Outflow | Training given to inspector regarding understanding of defects. | Mahesh G. | 27/08/2024 | 27/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | Na |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
NA 1034_Occurance_Before.pdf |
| Occurance (After) |
Cleaning freq. decided thrice in a shift and updated in CP. 1034_Occurance_After.pdf |
| Outflow (Before) |
NA 1034_Outflow_Before.png |
| Outflow (After) |
Awareness given to inspector. 1034_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All master cylinders |
12. Document Review
| Documents | ControlPlan, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 200 |
| Reason for submission | No blow hole found in 200 Nos lot. |