QFR No - 7000861486
Defect Details
| NC No. | 7000861486 |
| NC Date | 07/09/2022 |
| NC Submission Date | |
| Part No. | 520DZ00212 |
| Part Name | FORK BOLT K60-(DS181012) |
| Supplier Name & Code | 100348-SINGLA FORGING |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | THREADING NOT OK-Thread Taper |
1. Problem Description
| Defect Description | Quality issue of Thread Taper (Perpendicularity out w.r.t. to face). |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 960 |
| Is Defect Repeatative? | No |
| 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 |
1200
|
0
|
0
|
0
|
0
|
1200
|
| Check Qty |
1200
|
0
|
0
|
0
|
0
|
1200
|
| NG Qty |
960
|
0
|
0
|
0
|
0
|
960
|
| Scrap | 0 |
| Rework | 960 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1-Quality alert to be displayed at work station. 2-100% segregation of material at various stages to done in visual inspection with proper identification marking on part. |
3. Process Flow
| Process Flow Description |
|---|
| 1-Receipt of Raw Material 2-Received of Inspection 3-Storage 4-Part off Drilling 5-CNC 1st 6-CNC 2nd 7-M10 Tapping 8-Rolling 9-Plating (Out Source) 10-Final Inspection 11-Packing 12-Dispatch |
4. Process Details
| Process / Operation | Rolling |
| Outsource | No |
| Machine / Cell | Rolling machine |
| Machine / Cell No. | Rolling machine |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled | Checked and verified that skilled operator having skill level II is operating the machine. | O |
| Machine | Rolling die not matched | Checked and verfied that Setting approval is done as per control plan | O |
| Machine | Die rotate out | During verifcation it observed that Die was not rotate out as PM done as per PM plan. | O |
| Machine | Slide arm alignment out | During investigation it observed that slide is properly tight and taper can not produced in thread. | O |
| Machine | Part not guide properly in running operation | During investigation it observed that taper in thread made as part not guide properly during operati | X |
| Method | Inspection method inadequate | During investigation it observed 100% gaueg qualified in thread but taper in thread not detected | X |
| Method | Inspection frequency not adequate | During verfication it observed that hourly inspection is done in in-process | O |
| Man | Unawareness | Checked and observed that final checker is not aware to the defect-taper in thread | 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 | Part not guide properly in running operation |
| Why 2 | Rolling die mounting arm shaft revolving out. |
| Why 3 | Play in Arm Supporting Bearing/needle bearing |
| Why 4 | Bearing not replaced during PM. |
| Why 5 | During PM time bearing was OK |
| Root Cause (Occurance) | Part not guide properly in running operation because of Play in Arm Supporting Bearing/needle bearing as Bearing not replaced during PM. |
Root Cause Analysis (Outflow)
| Why 1 | Final checker is not aware to the taper in thread. |
| Why 2 | 100% gauge is qualifying in taper thread in part |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Final checker is not aware to the taper in thread as TRG is qualifying in the taper thread. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Play in arm to be verified physically during new setting | Shree Bhagwan | 10/09/2022 | 10/09/2022 | Completed |
| Outflow | Awareness Training to be provided to the final checker | Kamal Roy | 08/09/2022 | 08/09/2022 | Completed |
| Outflow | C.P to be revised for taper thread verification in final stage | Kamal Roy | 09/09/2022 | 08/09/2022 | Completed |
| Occurance | Taper thread to be verified during production | Kaml Roy | 10/09/2022 | 10/09/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection of taper in thread is started by qualifying the matting part till end and seeing the gap in between the part & matting part face physically. |
| Inspection Method | Other |
| Other Inspection Method | Matting part |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Thread Verified by gauge 248_Occurance_Before.pdf |
| Occurance (After) |
1-Thread verified by gauge and taper thread verified in visual & by matting part
2-Play in arm to be verified during setup time 248_Occurance_After.pptx |
| Outflow (Before) |
Thread Verified by gauge 248_Outflow_Before.pdf |
| Outflow (After) |
Thread verified by gauge and taper thread verified in visual & by matting part 248_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Fork Bolt Model |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | Quality Alert |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | Training record required for evidence |