QFR No - 7000870350
Defect Details
| NC No. | 7000870350 |
| NC Date | 12/10/2022 |
| NC Submission Date | |
| Part No. | S2HT12007B |
| Part Name | INNER SPRING_B104_E |
| Supplier Name & Code | 100834-LALJI GOPINATHJI INDUSTRIES |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | DIAMETER OVER SIZE-I/D Undersize in Inner Spring B104E |
1. Problem Description
| Defect Description | I/D Undersize in Inner Spring B104E (S2HT12007B). |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 238 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | std@lgindustries.co.in |
| Plant Head/CEO Email ID | rahulkumar@lgindustries.co.in |
| MD Email ID | lalit.k@lgindustries.co.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2968
|
0
|
0
|
1000
|
0
|
3968
|
| Check Qty |
2968
|
0
|
0
|
1000
|
0
|
3968
|
| NG Qty |
238
|
0
|
0
|
0
|
0
|
238
|
| Scrap | 238 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1-Immediate supply stopped only for next lot to verify the problem at our end.,2-All the pipeline parts seggrigated and NG parts removed from the shop flore.and.Only 100 % inspected material should be supplied to customer. |
3. Process Flow
| Process Flow Description |
|---|
| 1.Incoming Rm ,2- coiling .3-Tempring,4-greanding .5-shoot peening ,6-Recovery,7-secend Tempring ,8-powder caoting,9-PDI inspection ,10-Dispatch |
4. Process Details
| Process / Operation | PDI Stage |
| Outsource | No |
| Machine / Cell | CNC coiling m/c |
| Machine / Cell No. | CSK-690 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Gauge | To be verified in internal calibration std room by Micrometer found whithin spcifaction | O |
| Machine | coiling m/c | To be verified all cnc process parameter found ok within specification | O |
| Method | Inspection | Due to not proper checking inspection as par frequency | X |
| Man | Negligence of PDI inspector | PDI Inspector Negligence that they not do proper checked 100% | X |
| Material | RM | To be verified as par incoming inspection check sheet&With TC 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 | spring inner diameter under size |
| Why 2 | spring inner diameter under size found after Powder coating |
| Why 3 | spring inner Diameter Found lower side during coiling Lower side (29.9mm) |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | spring inner diameter found Lower side specification (29.90 mm-30.30mm) |
Root Cause Analysis (Outflow)
| Why 1 | spring inner diameter Found undersize |
| Why 2 | after powder coating 100 % inspection not proper done by PDI inspector |
| Why 3 | lack of Awareness of PDI about spring ID Fitment |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Due to PDI inspector negligence that they not do proper CHECKD by gauge |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Operator`s on the job training done shox assembly fitment parameter and OPL Display for fitment parameter on powder coating both ,and 100 % inspection to be verified on the PDI stage by QA inspector sampling basis | Mr.umesh tiwari and Sunil | 18/10/2022 | 18/10/2022 | Completed |
| Occurance | To maintain inner Diameter higher side within specification (30.10-30.30mm) | MR.Sunil | 18/10/2022 | 18/10/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | we have already 100% checked by PDI inspector But crossed verified after PDI stage checked sampling basis by QA |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | sam.plan |
10. Evidance of Countermeasure
| Occurance (Before) |
Before powder coating we have used this inner id gauge within specification (29.25-29.90 mm) 283_Occurance_Before.jpg |
| Occurance (After) |
To be interduce new gauge for before powder coating stage and specification within (30.00-30.30) 283_Occurance_After.jpg |
| Outflow (Before) |
operator not proper aware for shox assembly fitment at the PDI Stage, no sampling plan after inspection 283_Outflow_Before.pdf |
| Outflow (After) |
1-Proper training is given to PDI inspector for inner dia fitment issue ,2-Samplening plan is made for after final inspection ,3-WI/OPL Displayed for 100% inner dia inspection at relevent stage 283_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | spring division |
12. Document Review
| Documents | ControlPlan, WISOP |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | Found OK |