QFR No - 7000829339
Defect Details
| NC No. | 7000829339 |
| NC Date | 02/04/2022 |
| NC Submission Date | |
| Part No. | F2DZ08810B |
| Part Name | K0PG FORK BOLT |
| Supplier Name & Code | 100189-SANGKAJ STEEL PVT LTD. |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | DIMETER UNDERSIZE-Grove Dia 22.45-0.1 found Under Size |
1. Problem Description
| Defect Description | Grove Dia Under NG ( Under Size & Over Size) |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 2400 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | maheshmishra@sangkaj.com |
| Plant Head/CEO Email ID | steel@sangkaj.com |
| MD Email ID | anirudh.2007@hotmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
4800
|
0
|
0
|
2000
|
2000
|
8800
|
| Check Qty |
4800
|
0
|
0
|
2000
|
2000
|
8800
|
| NG Qty |
4800
|
0
|
0
|
0
|
0
|
4800
|
| Scrap | 0 |
| Rework | 4800 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Pipeline material 100% checked with DVC |
3. Process Flow
| Process Flow Description |
|---|
| Inward-Parting-CNC 1st -CNC 2nd -Palting -final inspection -Dispatch |
4. Process Details
| Process / Operation | CNC MACHINING |
| Outsource | No |
| Machine / Cell | CNCN CELL |
| Machine / Cell No. | 38 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Insert plunge 2 time | Not ok | X |
| Man | New manpower | Manpower is old | O |
| Machine | Machine under maintenance | Machine found ok | O |
| Tool | Tool life is not maintain | Tool life is maintain | O |
| Material | Material change | Material is not changed | 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 | 50 |
7. Root Cause Analysis (Occurance)
| Why 1 | Groove OD observed undersize due to insert is plunge 2 times |
| Why 2 | Insert plunge 2 times because of that taper is observed in groove OD. |
| Why 3 | standard insert is not available for size 3.00+0.2 mm . |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | standard insert is not available for size 3.00+0.2 mm . |
Root Cause Analysis (Outflow)
| Why 1 | Groove OD observed undersize |
| Why 2 | Sampling inspection |
| Why 3 | Material checked with snap gauge |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Material checked with snap gauge |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 3 mm insert plunge in one time and linear 0.1 mm machining then step is not found and taper also not observed. | Santosh raut | 26/04/2022 | 26/04/2022 | Completed |
| Outflow | 100% material checked with snap gauge. Also sampling with DVC out of 100/1000. In in process inspection hourly inspection with only DVC | Mahesh Mishra | 28/04/2022 | 28/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% material checked with snap gauge. Also sampling with DVC out of 100/1000. In in process inspection hourly inspection with only DVC |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 00 |
10. Evidance of Countermeasure
| Occurance (Before) |
insert plunge 2 times 39_Occurance_Before.jpg |
| Occurance (After) |
insert plunge 1 time and linear machining 39_Occurance_After.jpg |
| Outflow (Before) |
Material 100% inspect with snap gauge 39_Outflow_Before.jpg |
| Outflow (After) |
material inspect with DVC 39_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | WISOP |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 0 |
| Reason for submission | ETL Return Material stock details and actions are not given. All 4m to be addressed and fact verification to be corrected. Root Cause is not adequate (both Flow and Occurrence) i.e. why not detected at Setup inspection, Petro inspection sheet, PDIR etc. ? If tool double plunged then why 4M change not followed ? Occurrence side corrective action is given but preventive action is not defined i.e. How to avoid repeating of use of Non Standard tool. All Updated or Reviewed Documents to be uploaded (OPL, Training records, Control Plan etc.) |