QFR No - 7000851996
Defect Details
| NC No. | 7000851996 |
| NC Date | 27/07/2022 |
| NC Submission Date | |
| Part No. | S2KH01502B |
| Part Name | REBOUND SPRING K55G |
| Supplier Name & Code | 100185-HELICAL SPRINGS |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | SHARP EDGE & BURR-sharp Edge at end coil Id |
1. Problem Description
| Defect Description | Sharp edge at end coil cutting edge towards ID |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 1384 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | soaojfrmf1wdcyj03sjjik14.jpg |
Supplier Communication Details
| Quality Head Email ID | Prabhat@helicalsprings.in |
| Plant Head/CEO Email ID | awadhwa@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 |
20000
|
15000
|
0
|
10000
|
0
|
45000
|
| Check Qty |
20000
|
15000
|
0
|
10000
|
0
|
45000
|
| NG Qty |
1384
|
0
|
0
|
0
|
0
|
1384
|
| Scrap | 1384 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation of these material at customer end and our end. |
3. Process Flow
| Process Flow Description |
|---|
| R/M Inspection->Coiling->SR-1->Grinding->Shot peening->SR-2->Final Inspection-> Packing /Despatch |
4. Process Details
| Process / Operation | Coiling |
| Outsource | No |
| Machine / Cell | Coiling Machine |
| Machine / Cell No. | HTC-45B |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Competency level less | verify the skill matrix , competency level 4 | O |
| Machine | Setting problem | Verify the Set-up report found ok | O |
| Material | wire grade Ng | verify the setup report found ok | O |
| Method | checking method | verify the defect monitoring sheet | O |
| Tool | Shearing tool blunt | tool history card | X |
| Material | used wrong RM | verify the log found ok | O |
| Tool | feed roller was not working. | verify the history card found ok | O |
| Method | NG part handling was not adequate | Physically verify the NG part handling found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 0 |
7. Root Cause Analysis (Occurance)
| Why 1 | Sharp edge at the End Coil ID |
| Why 2 | Mandrill was not proper working. |
| Why 3 | During Coiling mandrel was blunt. |
| Why 4 | Operator was not check the mandrel Before completion of 50000 cycle. |
| Why 5 | Mandrel Checking frequency was define 50000 cycle to cut spring after completion of 50,000 cycle than operator was checked the mandrel. |
| Root Cause (Occurance) | After simulation , during run the machine Observed the mandrel , mandrel was blunt before completion 50000 cycle. but here mandrel checking frequency define after completion of 50000 cycle. |
Root Cause Analysis (Outflow)
| Why 1 | Sharp edge at the End Coil ID |
| Why 2 | This type of defect inspector did not capture. |
| Why 3 | Inspector was semi skilled . |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | After simulation observed the inspector negligence. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Provided the training all concern person. | Arunesh | 29/07/2022 | 29/07/2022 | Completed |
| Outflow | Depute the skilled person | Bharat | 01/08/2022 | 29/07/2022 | Completed |
| Outflow | Poison test organised | Bharat | 03/08/2022 | 29/07/2022 | Completed |
| Occurance | Revised the mandril frequency. 50000 replace to 40000. | Sumer | 01/08/2022 | 29/07/2022 | Completed |
| Occurance | Displayed the Quality alert . | Bharat | 29/07/2022 | 29/07/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | no |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 0 |
10. Evidance of Countermeasure
| Occurance (Before) |
Tool history card before customer complaint 210_Occurance_Before.jpg |
| Occurance (After) |
Tool history card after complaint. 210_Occurance_After.jpg |
| Outflow (Before) |
Was not fix the inspector 210_Outflow_Before.pptx |
| Outflow (After) |
Fix the operator 210_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | poison test monthly plan for critical parameter and customer complaint defect. |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 60000 |
| Reason for submission | 60000 nos. of Rebound spring K55G was checked 100% i.e. 2 lots in Nov 2022. No edge burr problem observed in both months of Nov 2022 & dec 2022. |