QFR No - 7000838558
Defect Details
| NC No. | 7000838558 |
| NC Date | 25/05/2022 |
| NC Submission Date | |
| Part No. | F1GN01102B |
| Part Name | MAIN SPRING K86A |
| Supplier Name & Code | 101225-HELICAL SPRINGS |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | PARALITY NOT OK.-Perpendicularity Out of Spec |
1. Problem Description
| Defect Description | Perpendicular NG i.e. observed 1.44, 1.37, 0.85 mm against the spec of 0.5 mm Max. |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 3400 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | 3jd0wsglcjllsqocql1hxmsz.jpg |
Supplier Communication Details
| Quality Head Email ID | ravindra@helicalsprings.in |
| Plant Head/CEO Email ID | shaikhmoin@helicalsprings.in |
| MD Email ID | ataneja@helicalsprings.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
15400
|
0
|
0
|
0
|
8450
|
23850
|
| Check Qty |
15400
|
0
|
0
|
0
|
8450
|
23850
|
| NG Qty |
15400
|
0
|
0
|
0
|
0
|
15400
|
| Scrap | 0 |
| Rework | 0 |
| Under Deviation | 15400 |
| Containment Action |
|---|
| All material used under deviation. we maintain e2 within spec 1.00 mm Max. |
3. Process Flow
| Process Flow Description |
|---|
| RM>Coiling>SR1>Grinding>Shotpeening>Setting>Correction>SR2>PDI>Packing>Dispatch. |
4. Process Details
| Process / Operation | Grinding |
| Outsource | No |
| Machine / Cell | Grinding |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Machine check Sheet not followed | CLIT verified found ok | O |
| Method | top and bottom grinding plate hole alignment not ok | Alignment found disturb | X |
| Man | unskilled Operator | Skill matrix checked found ok | O |
| Material | As per Drawing Not ok | RMTC verified found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 29/3201 |
7. Root Cause Analysis (Occurance)
| Why 1 | Perpendicularity Observed 0.7MM Against 0.5MM Max. |
| Why 2 | Due to taper grinding. |
| Why 3 | Top grinding plate position disturb w .r. t. bottom grinding plate |
| Why 4 | Single nut locking system available |
| Why 5 | |
| Root Cause (Occurance) | Single nut locking system available |
Root Cause Analysis (Outflow)
| Why 1 | Perpendicularity Observed 0.7MM Against 0.5MM Max |
| Why 2 | No inspection for e2 |
| Why 3 | No check point in line inspection for e2 |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No check point in line inspection for e2 |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Additional locking pins provided into both plates to fix the position. | Mr. Niesh Kapure | 22/02/2022 | 21/02/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Introduced the perpendicularity in line inspection |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 23/3200 |
10. Evidance of Countermeasure
| Occurance (Before) |
Single nut locking system available 150_Occurance_Before.jpg |
| Occurance (After) |
Additional locking pins provided into both plates to fix the position 150_Occurance_After.jpg |
| Outflow (Before) |
No check point in line inspection for e2 150_Outflow_Before.pdf |
| Outflow (After) |
Introduced the perpendicularity in line inspection 150_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All main Spring |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | Patrolling Insp |
13. Effectiveness Of Action
| Reviewed Quantity | 0 |
| Reason for submission | ok |