QFR No - 7000909710
Defect Details
| NC No. | 7000909710 |
| NC Date | 15/04/2023 |
| NC Submission Date | |
| Part No. | 520BD00102 |
| Part Name | BOTTOM CAP |
| Supplier Name & Code | 100165-SAPTAGIRI INDUSTRIES |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | M/CING SHIFT.-Flat Distence 3.5 found not ok(uneven) |
1. Problem Description
| Defect Description | Bottom cap observed with offset punching concern. This is repetitive concern in all models & may leads to fitment NG at end customer end. |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 6000 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@saptagirigroup.in |
| Plant Head/CEO Email ID | production@saptagirigroup.in |
| MD Email ID | argandhi@saptagirigroup.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
6000
|
2000
|
0
|
0
|
7000
|
15000
|
| Check Qty |
6000
|
2000
|
0
|
0
|
7000
|
15000
|
| NG Qty |
6000
|
0
|
0
|
0
|
0
|
6000
|
| Scrap | 6000 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% material verified by visual inspection at all stages. |
3. Process Flow
| Process Flow Description |
|---|
| RM + Sheet sharing + Blanking + Forming + Trimming + OD turning |
4. Process Details
| Process / Operation | Forming |
| Outsource | No |
| Machine / Cell | PS/10 |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | New carbide bush parallelism not verified | Parallelism observed upto 1.0 mm | X |
| Man | Inspector not aware about the dim 3.5 mm | awareness training not provided to concern inspector | X |
| Man | Inspector not aware the straight portion | No Q-alert display at work place | X |
| Tool | New tool inspection not done | New tool installed without inspection | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Bottom cap offset punching observed |
| Why 2 | new carbide bush replace with old one(old bush ID observed 28.24 mm against 28.1+0.1 mm |
| Why 3 | Forming at one side |
| Why 4 | As installed new carbide bush, it has observed a tapper up to 1.0mm ( not parallel w.r.t. top.) |
| Why 5 | |
| Root Cause (Occurance) | As installed new carbide bush, it has observed a tapper up to 1.0mm ( not parallel w.r.t. top). |
Root Cause Analysis (Outflow)
| Why 1 | Offset punch parts detected at the customer end |
| Why 2 | Due to less awareness of the final inspector, defective parts skip from the final inspection |
| Why 3 | No awareness training was provided. No Q-alert display at the final inspection |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No awareness training was provided. No Q-alert display at the final inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Carbide bush verified for parallelism | Mr. Dhirajkumar | 29/04/2023 | 29/04/2023 | Completed |
| Occurance | Will made a SOP for carbide bush installation | Mr. Patel | 06/05/2023 | 06/05/2023 | Completed |
| Outflow | While production first part of the shift will verify by profile projector daily | Mr. Dhirajkumar | 29/04/2023 | 29/04/2023 | Completed |
| Outflow | Awareness training will provide to final inspector | Mr. Dhirajkumar | 29/04/2023 | 29/04/2023 | Completed |
| Occurance | At stored all carbide bush will verify for parallelism and other fitment parameter. | Mr. Patel | 06/05/2023 | 06/05/2023 | Completed |
| Occurance | Observed parallelism up to 1.0mm, It is rework by turning operation | Mr. Patel | 06/05/2023 | 08/05/2023 | Completed |
| Occurance | After rework carbide bush verified and observed 0.12mm | Mr. Patel | 06/05/2023 | 06/05/2023 | Completed |
| Outflow | Q-alert will display at every concern location( Machine shop, final inspection) | Mr. Dhirajkumar | 29/04/2023 | 29/04/2023 | Completed |
| Outflow | DO the feasibility for special gauge to verify bottom cap profile. | Mr. Dhirajkumar | 06/05/2023 | 06/05/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No any change |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Bush Parallelism not verifying 410_Occurance_Before.pptx |
| Occurance (After) |
Bush Parallelism verified 410_Occurance_After.pptx |
| Outflow (Before) |
Q-alert and training about uneven surfaces not given 410_Outflow_Before.pptx |
| Outflow (After) |
Q-alert and training about uneven surfaces given to concern manpower 410_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Press Machine 10 |
12. Document Review
| Documents | WISOP |
| Specify Other Document | SOP |
13. Effectiveness Of Action
| Reviewed Quantity | 10 |
| Reason for submission | Corrective action parts submission. |