QFR No - 7000829350
Defect Details
| NC No. | 7000829350 |
| 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 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 |
2400
|
0
|
0
|
2000
|
2000
|
6400
|
| Check Qty |
2400
|
0
|
0
|
2000
|
2000
|
6400
|
| NG Qty |
2400
|
0
|
0
|
0
|
0
|
2400
|
| Scrap | 0 |
| Rework | 2400 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% material inspect at my end blue identification mark provided on component. also material started 100% checking with snap gauge. |
3. Process Flow
| Process Flow Description |
|---|
| RM INWARD - PARTING - TURNING CNC1 - TURNING CNC2 - PLATING - FINAL INSPECTION - DISPATCH |
4. Process Details
| Process / Operation | CNC TURNING 2ND SETUP |
| Outsource | No |
| Machine / Cell | CNC MACHINE CELL |
| Machine / Cell No. | 38 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | INSERT WEAR OUT AND DOUBLE PUNCH | INSERT DOUBLE PUNCH | X |
| Method | INSERT LIFE NOT MONITORING | INSERT LIFE MONITORED FOUND OK | 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 | Grove OD undersize. |
| Why 2 | Insert double plunge for 3.10 mm slot making purpose. |
| Why 3 | Standard insert is not available |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Standard insert is not available so we punch insert 2 times in groove. |
Root Cause Analysis (Outflow)
| Why 1 | Grove OD undersize. |
| Why 2 | Not detected in 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 | Now we used 3 mm insert and 0.1 mm we linear machining. | Raut Santosh | 20/04/2022 | 26/04/2022 | Completed |
| Outflow | 100%c material inspect with Digital vernier and blue identification mark also provided | Mahesh Mishra | 20/04/2022 | 03/05/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Material 100 Inspect with Digital vernier against snap gauge. |
| 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) |
Standard insert is not available so we plunge insert 2 times in groove. 40_Occurance_Before.jpg |
| Occurance (After) |
Now we used 3 mm insert and 0.1 mm we linear machining. 40_Occurance_After.jpg |
| Outflow (Before) |
Material 100% inspect with snap gauge 40_Outflow_Before.jpg |
| Outflow (After) |
Material 100% inspect with digital vernier 40_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.) |