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Extra material on end Chamfer

Analysis Record [Analysis

Report]

Part No. Pin-A


Part name 002-C46-129
Situation of occurrence (phenomenon/content of complaint/number of
occurrences/details of disposition)

Issuing Dept.

Theme

7 (M)

ROHTAS FASTENER

18 (D)

16 (Y)

Approved Reviewed Prepared


Parveen

Vikas

Devander

Fact checking (parts check result/factor analysis/product quality status)

Problem Statement:- Extra material on end Chamfer


Complaint Receipt Date: 10.07.16
Place of Occurance:- Nissin Brake
Reject Qty.:- 548 Nos
Lot No./Lot Identification

MAN

M/C
Exclusion die wornout..

No contribution

Exclusion tool profile NG


Extra material on
end Chamfer.

No contribution
No contribution

METHOD

Identification of causes (mechanism of occurrence/reproduction test/5-whys analysis)

Countermeasure effect check (effect achievement)

Appropriateness of countermeasure (details/expected effects/PPA)


Date of countermeasure determination

Cold Forging:- No extrusion at Forging stage

Countermeasure determined by

Grinding:- No extrusion at Forging stage

7 /

18

2. Quality alert and awarness training given to all concern


sorter for defect.

Thread Tapping :-Ok

16

Vikas Kumar

1. Tool life shall be monitor and established on the basis of


average of three dies life.

CNC-1 & CNC-2 :-No extrusion at Forging stage

MATERIAL

Production certified material to be identified with an ok


shipped label

Flat Extrusion:- After actual simulation of part with the wornout tool ,Extra material
forward on the chamfer and in case of new ok tool no extra material
moved on chamfer.
Heat Treatment , Surface Treatment has no relation with Extrusion rocess so is discarded
Final Inspection:- After analysis it is observed that the defect part flow to customer due to
unawarness of defect by final inspection sorter.

Feedback to source (content reflected in system/framework)


1. PFMEA revised.--- 20 july 2016

5-Whys analysis (Conduct 5-whys analysis covering all factors to extract problems.)
1
2
Step
Description

Occurrence

Extra material on end Chamfer

Outflow

Extra material on end Chamfer


material flow to customer

060130

Extrusion tool profile NG

Extrusion tool wornout

Extrusion tool life not


established

Change of standards

Due to unawareness regarding


the defect
Retention period for original:
(M)
(Y)
<<Record Form Registration No. QS-1303-3-01>>
Feb. 11, 2011

ROHTAS FASTNERS LTD.


QUALITY ALERT

PART DESCRIPTION

Pin A

CUSTOMER

M/S NBI

FINISH

Plated

AREA/ RESPONSIBILITY

Extrusion Pressing/Final inspection

DATE

16.07.16

QUALITY ALERT REPORT: Serious customer complaints .

NOT OK
COMMENTS:
Extra material on chamfer of PIN-A.
Pin -A ,
.
THIS IS A CUSTOMER COMPLAINT.

OK

COMMENTS:
Extra material Allowed on chamfer of PIN
P

PREPARED BY:
Davender

APPROVED BY
Vikas Kumar

ASTNERS LTD.

Pin A
M/S NBI
Plated
Extrusion Pressing/Final inspection
16.07.16

er complaints .

OK
COMMENTS:
No
Extra material Allowed on chamfer of PIN.
Pin

APPROVED BY
Vikas Kumar

SR. NO.

SYMBOL

PROCESS DESCRIPTION

10

Incoming Raw Material Inspection & Stor

20

Cold Forging & Line Inspection

30

Grinding & Line Inspection

40

CNC Turning -1 & Line Inspection

50

CNC Turning -2 & Line Inspection

60

Thread Tapping & Line Inspection

70

Flat Extrusiont & Line Inspection

80

Heat Treatment & Line Inspection

90

Grinding -2 & Line Inspection

100

Surface Treatment

110

Final Inspection

120

Packing, Storage & Despatch

SYMBOL TO BE USED

FINAL INSPECTION

OPERATION

OPERATION WITH
SIMULTANEOUS INSPECTION

SS DESCRIPTION
Material Inspection & Storage

& Line Inspection

e Inspection

1 & Line Inspection

2 & Line Inspection

g & Line Inspection

t & Line Inspection

nt & Line Inspection

Line Inspection

Home

ment

ge & Despatch

BE USED

STORAGE/ DESPATCH
TRANSPORTATION

FISHBONE DI
FISHBONE DIAGRAM FOR DEFECT: Extra material on end Chamfer

MACHINE

MAN

MATERIAL

Uncontrolled
worn out
Unawareness

Process

Extrusion
Die
Damage

Operator
New Operator

Chemistry low of
spec..
R.M.

Not Followed

Chemistry More
than Spec.
Within Spec

S.O.P
Not Available

Decarb Level

Material Fal
Material strike on
outlet wall

More than
Spec.
MATERIAL

mix with ok pa

METHOD

MEASUR

SHBONE DIAGRAM
Date :

MATERIAL HANDLING

18.07.2016

Home

Uncontrolled
Process
Not Effective
Not Frequented
Maintenance
Not Effective

mix with ok parts


Material Falling

Process
Specification

ial strike on
wall

Product
MEASUREMENT

Extra material on
end Chamfer

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