QFR No - 7000836634
Defect Details
| NC No. | 7000836634 |
| NC Date | 17/05/2022 |
| NC Submission Date | |
| Part No. | F2LY00312B |
| Part Name | SOCKET HEADED BOLT M8 - PRECOTE |
| Supplier Name & Code | 100348-SINGLA FORGING |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | LEAKAGE- |
1. Problem Description
| Defect Description | Uneven face/cut marks of Copper Washer resting area in Socket Head Bolt (F2LY00312B). |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 1701 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | pntquality@singlaforging.in |
| Plant Head/CEO Email ID | deepakgupta@singlaforging.com |
| MD Email ID | jain@singlaforging.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
17000
|
0
|
0
|
5000
|
12000
|
34000
|
| Check Qty |
17000
|
0
|
0
|
5000
|
12000
|
34000
|
| NG Qty |
1701
|
0
|
0
|
86
|
47
|
1834
|
| Scrap | 1834 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1-100% segregation of material lying at various stages is started with OK confirmation marking. 2- Quality Alert to be displayed at the work station. |
3. Process Flow
| Process Flow Description |
|---|
| Operation /No Operation:- 10 -Receipt of Material , 20- Forging, 30- Thread Rolling, 40- Heat Treatment, 50- Packaging and dispatch, 60-Receipt of forging, 70-incoming inspection, 80-Storage, 90-Surface treatment,100-Final Inspection,110-Packaging,120-Dispatch |
4. Process Details
| Process / Operation | Forging |
| Outsource | Yes |
| Machine / Cell | Forging |
| Machine / Cell No. | Forging |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Wrong material | Raw Material used as per drawing with all Quality Parameters Checked | O |
| Man | Unskilled & unaware | Inspector was not detect defective part as the part is in Black Condition so it was difficult to Obs | O |
| Method | Inspection frequency not adequate | Checked and verfiied ispection frequecy followed as per control plan 05 Pcs per Hour | O |
| Method | NG part mix woth ok part | Saperate location for OK and NG part, Red Bins Provided @ Forging Stage | O |
| Machine | Tool life not follow | Checked and verified tool life monitored and followed but Need to be Validated as Complaint is rais | X |
| Machine | Setup error | checked and verified setting procedure followed for setting | O |
| Machine | Die Crack mark | Check and found that die got cracked in running production | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | Samp. Plan |
7. Root Cause Analysis (Occurance)
| Why 1 | The Problem Occurred @Cold Forging Stage of the manufacturing Sequence |
| Why 2 | Here Hex Socket ,Head Dia & Head Height are Formed in One Die |
| Why 3 | Due to the nature of the process There is a Heavy Load in Die So Chances are More for Die to get Wear |
| Why 4 | `Due to This Wear A Fine Line mark Was Created @ Bearing face |
| Why 5 | This Fine Line mark was difficult to identify in Black Condition during WIP Stage |
| Root Cause (Occurance) | Die got cracked in running production due to high load on-die during making the socket and head in one Die. |
Root Cause Analysis (Outflow)
| Why 1 | Defected Part not detected in final inspection stage |
| Why 2 | Inspection was as per sampling Plan. |
| Why 3 | This Fine Line mark was difficult to identify in Black Condition during WIP Stage |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | This Fine Line mark was difficult to identify as the part is in Black Condition during WIP Stages before Plating. After Plating Such Defects get Clearly Visible |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 2-OJT training to be provided to the operator to Understand the Problem, Its Impact & Countermeasures.. | Nishant | 01/07/2022 | 01/07/2022 | Completed |
| Outflow | 1-Quality Alert is displayed in final inspection stage | Nishant | 17/05/2022 | 17/05/2022 | Completed |
| Outflow | 2-Awareness training to be provided to the inspector to Understand the Problem, Its Impact & Countermeasures. | Nishant | 16/05/2022 | 17/05/2022 | Completed |
| Occurance | 1- Part M8X27 Head Forging Die`s Scheduled Maintenance to be Done At Forging of 1 Lacs Pcs with Light Polishing & Same will be Recorded in Die History card | Nishant Jangra | 01/07/2022 | 01/07/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Part M8X27 Head Forging Die`s Scheduled Maintenance to be Done At Forging of 1 Lacs Pcs with Light Polishing & Same will be Recorded in Die History card |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Quality alert to be displayed 121_Occurance_Before.pdf |
| Occurance (After) |
1- Part M8X27 Head Forging Die`s Scheduled Maintenance to be Done At Forging of 1 Lacs Pcs with Light Polishing & Same will be Recorded in Die History card
2-OJT training to be provided to the operator to Understand the Problem, Its Impact & Countermeasures.. 121_Occurance_After.pdf |
| Outflow (Before) |
Visual inspection done with naked eye 121_Outflow_Before.xlsx |
| Outflow (After) |
1-Quality Alert is displayed in final inspection stage
2-Awareness training to be provided to the inspector to Understand the Problem, Its Impact & Countermeasures. 121_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Bolt |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | OJT |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | found OK |