QFR No - 8000890049
Defect Details
| NC No. | 8000890049 |
| NC Date | 05/09/2024 |
| NC Submission Date | |
| Part No. | 52DR00505O |
| Part Name | FASTENING CAP TAPPED-FINISHED C101 CBS |
| Supplier Name & Code | 101261-BHOGALE AUTOMOTIVE PRIVATE LIM |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | LENGTH OVERSIZE-LUG HEIGHT OVERSIZE |
1. Problem Description
| Defect Description | LENGTH OVERSIZE-LUG HEIGHT OVERSIZE |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1020 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | nikhil.kulkarni@bhogaleauto.com |
| Plant Head/CEO Email ID | rajendra.randive@bhogaleauto.com |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1076
|
0
|
0
|
1200
|
0
|
2276
|
| Check Qty |
1076
|
0
|
0
|
1200
|
0
|
2276
|
| NG Qty |
494
|
0
|
0
|
570
|
0
|
1064
|
| Scrap | 0 |
| Rework | 1064 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1. Informed to production & inspection responsible. 2. 1076 nos verified for 1.5 mm distance at ETL. |
3. Process Flow
| Process Flow Description |
|---|
| Receipt inspection > Forging > Heat treatment > Trimming > Grinding > Drilling > Chamfering > Powder coating > Final inspection > Packaging & dispatch |
4. Process Details
| Process / Operation | Grinding |
| Outsource | No |
| Machine / Cell | Belt grinder |
| Machine / Cell No. | Belt grinder |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Belt supporting plate is not o | Supporting plate worn out and part on belt pressed in tapered manner | O |
| Method | Wrong holding of part for grinding | Due to wrong holding part grinding is tapered | O |
| Man | Part face ground tapered by operator | Due to manual process always possibility of taper. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10 nos |
7. Root Cause Analysis (Occurance)
| Why 1 | After coating dimension 1.5 mm (i.e. lug heights difference) found undersized. |
| Why 2 | In grinding lug heights and face not maintained. |
| Why 3 | While grinding at lug bottom face, surface formed tapered. |
| Why 4 | Grinding machine belt supporting plate worn out |
| Why 5 | Belt supporting plate check point not available. |
| Root Cause (Occurance) | Grinding machine belt supporting plate worn out. |
Root Cause Analysis (Outflow)
| Why 1 | After coating dimension 1.5 mm (i.e. lug heights difference) found undersized. |
| Why 2 | Defect not trace out in final inspection |
| Why 3 | In final inspection distance 1.5 mm checked as single point to point difference. Not con |
| Why 4 | Point to point difference on tapered portion not measured on height gauge pointer. |
| Why 5 | |
| Root Cause (Outflow) | Face to face difference on tapered portion not measured on height gauge pointer. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Inspection by vernier caliper implemented | NSK | 04/09/2024 | Completed | |
| Occurance | 1. Belt supporting plate to be changed. | BAPL | 05/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection by vernier caliper implemented in final inspection till issue resolved. |
| 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) |
Belt supporting plate worn out due to friction with the belt while pressing the part. 1082_Occurance_Before.png |
| Occurance (After) |
The supporting plate of belt grinder is to be replaced with new one. 1082_Occurance_After.png |
| Outflow (Before) |
Measurement carried out by height gauge. 1082_Outflow_Before.png |
| Outflow (After) |
Measurement method changed as vernier caliper from height gauge 1082_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PMCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | Improvement found in current lots |