QFR No - 7000860787
Defect Details
| NC No. | 7000860787 |
| NC Date | 03/09/2022 |
| NC Submission Date | |
| Part No. | S2KH03702B |
| Part Name | REBOUND SPRING B105L |
| Supplier Name & Code | 100185-HELICAL SPRINGS |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | DIMN.U/SIZE.-I/D UNDER AIZE SPE=11.20+0.30OBSER=10.88 |
1. Problem Description
| Defect Description | Rebound Spring B105L= I/D UNDER SIZE OBSER=10.88 |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 10000 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
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 |
8000
|
10000
|
0
|
5000
|
0
|
23000
|
| Check Qty |
8000
|
0
|
0
|
5000
|
0
|
13000
|
| NG Qty |
2500
|
0
|
0
|
0
|
0
|
2500
|
| Scrap | 2500 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% at lying material at our end at your end. |
3. Process Flow
| Process Flow Description |
|---|
| R/M->Coiling->SR-1->Grinding->Shot -peening->SR-2->Final Inspection-> Packing-> Despatch |
4. Process Details
| Process / Operation | Machine |
| Outsource | No |
| Machine / Cell | HTC-80 |
| Machine / Cell No. | HTC-80 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Competency of operator | verify skill matrix found >3 year exp. | O |
| Method | Inadequate gauge used | found Ng | X |
| Material | wire grade wrong used | log verify found ok | O |
| Machine | Setting error | Physically verify found ok | O |
| Tool | slide bolt was loose | physical verify found not ok | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | inner dia at spring body under size |
| Why 2 | Slide displacement unevenness |
| Why 3 | Excess play of slide |
| Why 4 | Slide bolt loose |
| Why 5 | checking frequency of bolt tightening only start of shift |
| Root Cause (Occurance) | Uneven displacement of slide at coiling stage. |
Root Cause Analysis (Outflow)
| Why 1 | Inner dia at spring body under size |
| Why 2 | Gauge was not adequate |
| Why 3 | Only checked the 100% inner dia 10.65~10.85 |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Only checked the Inner dia 100% with gauge dim 10.65~10.85 mm |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | bolt tightening frequency revised now we checked the bolt tightening twice in a day. | sumer | 07/09/2022 | 06/09/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Both ID checked with assembly gauge. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Before we checked the bolt tightening once in a day 241_Occurance_Before.png |
| Occurance (After) |
Now we checked the bolt tightening twice in a day. 241_Occurance_After.jpg |
| Outflow (Before) |
We used a adequate gauge 241_Outflow_Before.jpg |
| Outflow (After) |
we used assembly gauge . 241_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Bolt tightening frequency Revised for all part |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | Evidence of Occurrence Countermesure Before & After are same ( Need To Correct ) However No Defective Parts Observed after Action Taken. |