QFR No - 8000889502
Defect Details
| NC No. | 8000889502 |
| NC Date | 02/09/2024 |
| NC Submission Date | |
| Part No. | 550PH00412 |
| Part Name | VALVE RETAINER |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-CUT MARK |
1. Problem Description
| Defect Description | Grinding damage |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 3 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@mahavirind.co.in |
| Plant Head/CEO Email ID | planthead@mahavirind.co.in |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
750
|
0
|
0
|
0
|
1800
|
2550
|
| Check Qty |
750
|
0
|
0
|
0
|
1800
|
2550
|
| NG Qty |
3
|
0
|
0
|
0
|
0
|
3
|
| Scrap | 3 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Suspected Material Segregation at Customer End |
3. Process Flow
| Process Flow Description |
|---|
| RM Inward - Store- Parting on Traub Machine - CNC counter boring and facing - OD Grinding- plating-- Final Inspection - Dispatch |
4. Process Details
| Process / Operation | OD Grinding |
| Outsource | No |
| Machine / Cell | CLG Grinding Section |
| Machine / Cell No. | CLG-5 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Process &Inspection Method Wrong | Process Method Ok But Inspection Method After OD Grinding visual frequency Very Low | X |
| Man | Unskilled operator | As per Skilled Matrix Operator is Skilled | O |
| Material | Hard And other grade Material Use | Hardness 80-94 HRB and as per required grade CEW-3 Material Use. | O |
| Tool | Wrong Grinding Wheel Use and work Rest blade | As Per Store Record Ok CUMI Make Grinding Wheel Use.But Work Rest Blade Thickness Not Ok | X |
| Machine | Machine Condition Not oK or RPM over | Machine Condition ok But Control Wheel RPM was 35--45 | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | NOT AS PER SPECIFICATION-CUT MARK |
| Why 2 | As per part diameter size Work Rest Blade Not use |
| Why 3 | Part Damage During part feeding on OD Grinding Process. |
| Why 4 | Part Not Proper Rest on work rest blade during OD Grinding process On Grinding Machine |
| Why 5 | Work Rest Blade Thickness was Under size Instead of Required Thickness . |
| Root Cause (Occurance) | Work Rest Blade Thickness was Under size |
Root Cause Analysis (Outflow)
| Why 1 | NOT AS PER SPECIFICATION-CUT MARK |
| Why 2 | Final Inspection stage Not Detect During Visual sampling Inspection |
| Why 3 | After OD Grinding Process & Final Inspection stage visual frequency Very Low |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | After OD Grinding Process & Final Inspection stage visual frequency Very Low |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Sampling Frequency Increase 100% per 500nos Bag Instead Of 20/500nos& After Visual Inspection Tick Marks On OD at Final Stage. | Quality Head | 20/09/2024 | 21/09/2024 | Completed |
| Occurance | Work Rest blade Thickness Increase 20insted Of 10mm | Production Head | 04/10/2024 | 03/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Previously, the price was 20 nos per bag; now it is 100% per bag. Inspection |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Work Rest Blade Thickness was Under size 1059_Occurance_Before.jpg |
| Occurance (After) |
Work Rest blade Thickness Increase 20mm instead of 10mm 1059_Occurance_After.jpg |
| Outflow (Before) |
After OD Grinding Process & Final Inspection stage visual frequency Very Low 1059_Outflow_Before.docx |
| Outflow (After) |
Sampling Frequency Increase 100% per 500nos Bag Instead Of 20/500nos& After Visual Inspection Tick Marks On OD at Final Stage. 1059_Outflow_After.docx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Valve Retainers models |
12. Document Review
| Documents | ControlPlan, PFMEA, InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | OK |