Countermeasure 43141 KTE 6700

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)
MQCQ - FO - 0001
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

MQCQ - FO - 0001
S.NO LOCATION QTY. CHECKED
1 Forging WIP 10
MQCQ - FO - 0001
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
MQCQ - FO - 0001
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
MQCQ - FO - 0001
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.)
MQCQ - FO - 0001
HONDA MOTO
Analysis record [ Problem Analys
PROBLEM CONTENTS: Dimension Failu

MQCQ - FO - 0001
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:

MQCQ - FO - 0001
SR.
NG PARTS POSSIBLE CAUSES
NO
Extrusion angle not taken in

5 1 consideration during forging
for next oprn.
2 Die length undersize

MQCQ - FO - 0001
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.
MQCQ - FO - 0001
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

MQCQ - FO - 0001
Low awareness of F.I inspector.

MQCQ - FO - 0001
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

MQCQ - FO - 0001
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
MQCQ - FO - 0001
VERIFICATION Results Summery of change points
Actual part verified and found

NG NG
Actual Die verifiied and found

OK. OK
MQCQ - FO - 0001
, expected Results)
TARGET DATE
Done
MQCQ - FO - 0001
TARGET DATE
. Done
4 5
Design not validated as

per next CNC operation
MQCQ - FO - 0001
MQCQ - FO - 0001
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
MQCQ - FO - 0001
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
MQCQ - FO - 0001
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.
MQCQ - FO - 0001
Confirmation of effectiveness ( Actual Results After Counter Measure Taken )
CONFIRMATION RESULTS OF 3 SUBSEQUENT LOTS AFTER COUNTERMEASURE
S.NO. DATE INVOICE NO.
3
MQCQ - FO - 0001
Occurrence C/M(Before)
Feedback (Contents to be reflected in the
Tool Drawing
Process Drawing
Operation Standard(I.R)
MQCQ - FO - 0001
MQCQ - FO - 0001
Date:
HMSI
Approval Check
ble date ]
m. 3.00 Max Observation 3.62

-1.00 observation 34.92
MQCQ - FO - 0001
GAP
PROBLEM
Dimension Failure Sample Failure
GAP
PROBLEM
Design not validated Sample Failure
CAUSE ANALYSIS
MQCQ - FO - 0001
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.
MQCQ - FO - 0001
NTERMEASURE
LOT QTY. STATUS REMARK

MQCQ - FO - 0001
be reflected in the systems / procedures )

MQCQ - FO - 0001
Before After
AS per Old Design calculation
15
2.5~4.00
AS per New Design calculation
20
2.0~3.00

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MQCQ - FO - 0001

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

PART NUMBER 43141-KTE-6700

PART NAME Cam Brake Rear

Dim. Failure(3.00 Max. & Dim

2 .PLACE OF OCCURANCE HMSI

4. DATE OF OCCURANCE 20.06.17

5. NUMBER OF CASES (Sample Lot)05 Pcs

Material packed as Finish Good checked again for leakage det

S.NO LOCATION QTY. CHECKED

A. OCCURANCE ROOT CAUSE

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

B.OUT FLOW ROOT CAUSE

Analysis record [ Problem Analys

PROBLEM CONTENTS: Dimension Failu

Plating Final Inspection

kage details as below:

Extrusion angle not taken in

2 Die length undersize

em analysis ) Counter Measure Taken ( Measure contents, exp

D. OUT FLOW COUNTERMEASURE

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

Extrusion Angle Length over Extrusion Angle was 15

Low awareness of F.I inspector.

TORCYCLE & SCOOTER (INDIA) PVT. LTD.

[ Identified facts result of verification, cause analysis

ailure Specification :- Dim. Failure(3.00 Max

VERIFICATION Results Summery of change points

Actual part verified and found

Actual Die verifiied and found

Design not validated as

Responsibility Approved Make

use analysis, manufacturing quality status on the applicable date ]

ACTUAL: Dim. 3.00 Max

Dimension fall outside

DEFECT : Dimension failure at Custom

Confirmation of effectiveness ( Actual Results After Counter Measure Taken )

CONFIRMATION RESULTS OF 3 SUBSEQUENT LOTS AFTER COUNTERMEASURE

S.NO. DATE INVOICE NO.

Feedback (Contents to be reflected in the

m. 3.00 Max Observation 3.62

Dimension Failure Sample Failure

Design not validated Sample Failure

al situation of defect analysis it is

ction Inspector considered these dim.

LOT QTY. STATUS REMARK

be reflected in the systems / procedures )

AS per New Design calculation

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