QFR No - 7000847161
Defect Details
| NC No. | 7000847161 |
| NC Date | 06/07/2022 |
| NC Submission Date | |
| Part No. | 550BZ05802 |
| Part Name | CAP OIL LOCK -PRFH006 |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | DEPTH O/SIZE.-Depth over size |
1. Problem Description
| Defect Description | Depth found Over size Observed 7.20,7.34 against 7±0.10 mm |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 114 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@apw3.co.in |
| Plant Head/CEO Email ID | kurund.ma@sharp-engineers.com |
| MD Email ID | urkhandelwal@sharp-engineers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
29000
|
0
|
0
|
5000
|
0
|
34000
|
| Check Qty |
29000
|
0
|
0
|
5000
|
0
|
34000
|
| NG Qty |
114
|
0
|
0
|
5
|
0
|
119
|
| Scrap | 0 |
| Rework | 119 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done for all the pipeline material & Dial type gauge made available in place of PPG on all the stages & Stage wise skill matrix defined for operator. Q gate license implemented for inspectors. OPL displayed on machine as well as inspection stages. |
3. Process Flow
| Process Flow Description |
|---|
| 10) Parting ,Drilling & angle 2.7° 20) Ø8.50 chamfering 30) Grinding Operation 40) Plating, 50) Final Inspection, 60) Pre-dispatch inspection, 70) Packing & Dispatch |
4. Process Details
| Process / Operation | 10) Parting ,Drilling & angle 2.7° |
| Outsource | No |
| Machine / Cell | TRAUB MACHINE SHOP |
| Machine / Cell No. | SE/ALM/03 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Semi-skilled manpower, inadequate knowledge of process/operations | Semi-skilled operator was working on machine for parting & drilling operation. | O |
| Tool | worn out | Tool life monitoring exist | O |
| Material | Bend bar in the raw material | bar observed bend at machining stage. | X |
| Method | 100%Checking by relation type gauge, Dial type gauge required for sampling inspection. | Dial type gauge not evident for sampling basis inspection. | X |
| Machine | inaccurate machine/variations in machine | All the machine are ok and preventive maintenance being done as per defined frequency. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Dial type gauge . |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
7. Root Cause Analysis (Occurance)
| Why 1 | DIM 7.0+/-0.1 under size |
| Why 2 | Bar bend (Raw material Ø18.05) & uneven movement while machining. |
| Why 3 | Excess bar length 5-6 meter |
| Why 4 | Length requirement not given to RM supplier |
| Why 5 | |
| Root Cause (Occurance) | Excess length of bar Ø18.05mm (5-6 meter) |
Root Cause Analysis (Outflow)
| Why 1 | DIM 7.0+/-0.1 under size |
| Why 2 | Inspection by Spl. concentricity checking gauge |
| Why 3 | Attribute type gauge |
| Why 4 | Dial type gauge not available. |
| Why 5 | |
| Root Cause (Outflow) | Dial type gauge not in used while checking DIM 7.0+/-0.1mm. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Dial type gauge and comparator stand provided for sampling basis inspection as per SSPN IS:2500 | Mr. Shaikh L..N | 11/07/2022 | 08/07/2022 | Completed |
| Occurance | Raw material ena1a Ø18.05mm total length reduced from 5/6 meter to 3/4 meter. | Mr. Datta Pandher | 11/07/2022 | 08/07/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Dial type gauge and comparator stand provided for sampling basis inspection as per SSPN IS:2500 and 100% inspection by Spl. concentricity checking gauge. |
| Inspection Method | Other |
| Other Inspection Method | Dial type gauge. |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 32:1200 |
10. Evidance of Countermeasure
| Occurance (Before) |
Excess length of bar Ø18.05mm (5-6 meter). 192_Occurance_Before.jpg |
| Occurance (After) |
Bar length of raw material Ø18.05mm reduced from 5/6 meter to 3/4 meter. 192_Occurance_After.jpg |
| Outflow (Before) |
Inspection by Spl. concentricity checking gauge, Dial type gauge not in used while checking DIM 7.0+/-0.1mm. 192_Outflow_Before.pptx |
| Outflow (After) |
Dial type gauge and comparator stand provided for sampling basis inspection as per SSPN IS:2500 192_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | CAP OIL LOCK LML/ DF |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | OK |