MQCQ - FO - 0001

Documentation Instruction

THEME Dim. Failure(3.00 Max. & Dim 34.00)

PART NUMBER 43141-KTE-6700

PART NAME Cam Brake Rear

[ Situation Event Symptom, Complaints, Number of occurrences, actions ]

Dim. Failure(3.00 Max. & Dim

1. TYPE OF OCCURANCE
34.00)
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2 .PLACE OF OCCURANCE HMSI

3. CONDITIONS AND
CIRCUMSTANCES OF PROBLEM Problem reported from HMSI 1F
WHEN IT OCCURED

4. DATE OF OCCURANCE 20.06.17

5. NUMBER OF CASES (Sample Lot)05 Pcs

DETAILS :-

Material packed as Finish Good checked again for leakage det

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S.NO LOCATION QTY. CHECKED

1 Forging WIP 10
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Root Cause of Problem ( How the Problem occurred, duplication test, problem analy

A. OCCURANCE ROOT CAUSE

After verification of physical part it is analysed that during forging proc

1
more due to angle of 15. Which is not validated as per n
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B.OUT FLOW ROOT CAUSE

2A
During inspection at F.I dim. Checked and taken as ok on min. sid
during Insp.)

2B

2C

Problem analysis

Step 1

Dimension Failure
Req 3.00 Max
Obs. 2.81~3.65 mm
C Occurrence Req. Dim. 35.00 - 1.00
o Obs 35.00 - 1.25
n
t
e
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C
o
n
t
e
n During inspection at F.I dim.
t
s Checked and taken as ok on
Outflow
min. side(Max. length not
considered during Insp.)
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HONDA MOTO

Analysis record [ Problem Analys

PROBLEM CONTENTS: Dimension Failu

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PROCESS FLOW DIAG

Raw material
Rec.and Inspection Forging

CNC-2 CNC-1

Plating Final Inspection

(M/S S.K Int.)

Problem
Occurred
Here

kage details as below:

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SR.
NG PARTS POSSIBLE CAUSES
NO

Extrusion angle not taken in

5 1 consideration during forging
for next oprn.

2 Die length undersize

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em analysis ) Counter Measure Taken ( Measure contents, exp

C. OCCURANCE COUNTERMEASURE

ing process length of extrusion angle was 1A Process & Tool drawing revised
as per next CNC opreation.
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D. OUT FLOW COUNTERMEASURE

min. side(Max. length not considered 2A Training Provided to F.I Person.

2 3

Extrusion Angle Length over Extrusion Angle was 15

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Low awareness of F.I inspector.

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TORCYCLE & SCOOTER (INDIA) PVT. LTD.

Department or supplier name
ysis Sheet ]
Made by
RFL

[ Identified facts result of verification, cause analysis

ailure Specification :- Dim. Failure(3.00 Max

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DIAGRAM :-
OCCURANCE
Problem Not
Detect Here STANDARD
Notching
Dimension Failure
Req 3.00 Max
Obs. 2.81~3.65 mm
Heat Req. Dim. 35.00 - 1.0
Treatment Obs 35.00 - 1.25

OUTFLOW
STANDARD
Packing and
tion Dispatch

Dimension should be w
em
tolerance
red
e

FACTS VERIFICATION
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VERIFICATION Results Summery of change points

Actual part verified and found

NG NG

Actual Die verifiied and found

OK. OK
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, expected Results)

TARGET DATE

Done
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TARGET DATE

. Done

4 5

Design not validated as

per next CNC operation
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T. LTD.
Date ( Y/M/D ) 09.02.2017

Responsibility Approved Make

Rohtas Fasteners
Vijay Kumar Vikas
Pvt Ltd.

use analysis, manufacturing quality status on the applicable date ]

ACTUAL: Dim. 3.00 Max

e(3.00 Max. & Dim 34.00)
Dim. 35.00 -1.00 observati
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GAP
ANDARD ACTUAL

sion Failure
3.00 Max
Obs. 2.81~3.65 mm Dimension Fail
81~3.65 mm Obs 35.00 - 1.25
. 35.00 - 1.00
5.00 - 1.25
GAP
ANDARD ACTUAL

Dimension fall outside

should be within Design not val
lerance against specified
tolerance

CAUSE ANALYSIS
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DEFECT : Dimension failure at Custom

ROOT CAUSE :
After verification of actual situation o
found that during forging extrusion ang
consideration which is resulting in dim
operation (CNC)
FLOW:
At the time of final inspection Inspect
from below sides of measurement.
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Confirmation of effectiveness ( Actual Results After Counter Measure Taken )

CONFIRMATION RESULTS OF 3 SUBSEQUENT LOTS AFTER COUNTERMEASURE

S.NO. DATE INVOICE NO.

3
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Occurrence C/M(Before)

Feedback (Contents to be reflected in the

Tool Drawing
Process Drawing
Operation Standard(I.R)
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Date:

HMSI
Approval Check

ble date ]

m. 3.00 Max Observation 3.62

-1.00 observation 34.92
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GAP
PROBLEM

Dimension Failure Sample Failure

GAP
PROBLEM

Design not validated Sample Failure

CAUSE ANALYSIS
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e at Customer end

al situation of defect analysis it is

xtrusion angle length not taken in
ulting in dimension failure at next

ction Inspector considered these dim.

rement.
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NTERMEASURE

LOT QTY. STATUS REMARK

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be reflected in the systems / procedures )

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Before After
AS per Old Design calculation

15

2.5~4.00

AS per New Design calculation

20

2.0~3.00