QFR No - 7000909764
Defect Details
| NC No. | 7000909764 |
| NC Date | 17/04/2023 |
| NC Submission Date | |
| Part No. | B2RW00226O |
| Part Name | PISTON ACTUATOR REGULAR 32.1 MM |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1156-ETL Disc Brake P'Nagar |
| Defect Details | LENGTH UNDERSIZE- |
1. Problem Description
| Defect Description | Length short issue |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 54 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@apw3.co.in |
| Plant Head/CEO Email ID | kurund.ma@sharp-engineers.com |
| MD Email ID | urkhandelwal@sharp-engineers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5000
|
5000
|
0
|
2000
|
0
|
12000
|
| Check Qty |
5000
|
5000
|
0
|
0
|
0
|
10000
|
| NG Qty |
54
|
2
|
0
|
0
|
0
|
56
|
| Scrap | 0 |
| Rework | 56 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done immediately at ETL pipeline material and warehouse material. |
3. Process Flow
| Process Flow Description |
|---|
| 10) RM Inward 20) Parting & Forming 30) Forming 40) Plating Process (Outsource) 50) Inward inspection 60) Storage 70) Final Inspection |
4. Process Details
| Process / Operation | Forming Process |
| Outsource | No |
| Machine / Cell | Traub Section |
| Machine / Cell No. | SE/SO/01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Incorrect RM grade | Third part inspection verified for chemical composition and hardness testing as per requirement. | O |
| Method | PISTON ACTUATOR-MODIFIED checking by single ended snap gauge. | Sampling basis inspection as per IS:2500 and inspection done by vernier caliper.. | X |
| Tool | Excess use of forming tool/Tool worn out. | Tool life monitoring as per defined frequency and record updated | O |
| Machine | Inadequate check Point in JH check sheet | Monthly JH check sheet available on machine and all the check point is being checked and recorded as | O |
| Man | Judgment error While checking | Master sample/ Limit sample provided for Checking at final as well as process stage | 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 | 1:1 |
7. Root Cause Analysis (Occurance)
| Why 1 | Wrong part Piston Actuator KHI (B2RW00326O) mix up with PISTON ACTUATOR-MODIFIED (B2RW00226O) |
| Why 2 | Single packing stage for both piston and both parts look like almost same. |
| Why 3 | Packing person inadequate knowledge and get confused while packing |
| Why 4 | OPL and Q alert not displayed at packing and inspection stage. |
| Why 5 | |
| Root Cause (Occurance) | Packing person inadequate knowledge of part and OPL Q alert not displayed at packing and inspection stage. |
Root Cause Analysis (Outflow)
| Why 1 | PISTON ACTUATOR-MODIFIED (B2RW00226O) mix up with Piston Actuator KHI (B2RW00326O) |
| Why 2 | Sampling basis inspection as per IS:2500 and checking done by vernier caliper. |
| Why 3 | No 100% inspection for piston actuator modified (B2RW00226O) |
| Why 4 | By system design |
| Why 5 | |
| Root Cause (Outflow) | No 100% inspection for piston actuator modified (B2RW00226O) |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Packing stages are identified for PISTON ACTUATOR-MODIFIED (B2RW00226O) and packing is being done at two different stage for both the pistons and OPL displayed. | Mr. Shaikh L.n. | 12/04/2023 | 12/04/2023 | Completed |
| Outflow | On job training given to packing person and inspectors , OPL and Q alert displayed at packing and inspection stage to avoid mix up issue, Standard SESG provided for inspection in place of digital vernier. | Mr. MD ansari/Mrs. Jadhav | 12/04/2023 | 12/04/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection by SESG (Single ended snap gauge) |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
Packing person inadequate knowledge of part and OPL Q alert not displayed at packing and inspection stage. 415_Occurance_Before.pptx |
| Occurance (After) |
Packing stages are identified for PISTON ACTUATOR-MODIFIED (B2RW00226O) and packing is being done at two different stage for both the pistons and OPL displayed. 415_Occurance_After.pptx |
| Outflow (Before) |
No 100% inspection for piston actuator modified (B2RW00226O) checking done by vernier caliper. 415_Outflow_Before.pptx |
| Outflow (After) |
On job training given to packing person and inspectors , OPL and Q alert displayed at packing and inspection stage to avoid mix up issue, Standard SESG provided for inspection in place of digital vernier. 415_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | ok |