QFR No - 7000932465
Defect Details
| NC No. | 7000932465 |
| NC Date | 26/07/2023 |
| NC Submission Date | |
| Part No. | 550BZ01402 |
| Part Name | CAP OIL LOCK - DF01 |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | PARALITY NOT OK.-Parallelism out of specification 0.04 mm |
1. Problem Description
| Defect Description | Parallelism NG of cap oil lock |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 2445 |
| 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 |
22000
|
20000
|
0
|
10000
|
0
|
52000
|
| Check Qty |
22000
|
20000
|
0
|
10000
|
0
|
52000
|
| NG Qty |
2445
|
0
|
0
|
6
|
0
|
2451
|
| Scrap | 0 |
| Rework | 2445 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done immediately for suspected material and defective 2445 nos rejected and quarantine from ok parts, |
3. Process Flow
| Process Flow Description |
|---|
| 10) RM Inward inspection 20) Storage 30) Parting, Drilling & Forming 40) Chamfering 50) OD Ø 18.05 grinding 60) Plating Process (Outsource) 70) Inward Inspection 80) |
4. Process Details
| Process / Operation | Parting, Drilling & Forming |
| Outsource | No |
| Machine / Cell | TRAUB MACHINE |
| Machine / Cell No. | SE/SSAL/01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Un-skilled Operator | Stage wise skill matrix and operator license are evident as per F/HR/06 | 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 |
| Method | Improper Material Flow | Material flow defined as per process flow and control plan and being followed | O |
| Tool | Tool life not getting as defined | Tool life is defined. But tool is found wear out before defined frequency. | X |
| Material | Incorrect Raw Material | Material observed as per customer requirement Ø16.10 EN1A , MTC verified as per drawing specificatio | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Sp. 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 | Tool worn out on 500/sharpening earlier than defined frequency , drill worn out sometimes at end of the tool life near @500 Nos. |
| Why 2 | In SS drill variation observed for parallelism at end of the tool life 500/sharpening. |
| Why 3 | |
| Why 4 | Drill life not getting as per defined frequency . |
| Why 5 | |
| Root Cause (Occurance) | CAP OIL LOCK (df) tool life defined for 500/sharpening but drill Ø14.10 worn out earlier than defined frequency. Dimensional variation found at end of the tool life after 500/sharpening. |
Root Cause Analysis (Outflow)
| Why 1 | Excess parallelism not detected at final inspection |
| Why 2 | Sampling basis inspection as per SSPN 32:1200 Nos. |
| Why 3 | Sampling frequency defined by system as per control plan. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | 100% inspection is not being done for parallelism. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | For TIN Coated Drill Initially 100% inspection will be done for parallelism to monitoring the results, after sustenance verification and joint discussion with ETL & SHARP inspection frequency will be changed . | Mr.Shaikh L.N. | 26/07/2023 | 27/07/2023 | Completed |
| Occurance | SS Tool life not getting as per defined so view of improvement in tool life inplace of SS TIN (Titanium Nitride ) coated drill is being used, SPC done for coated and non coated drill after process validation TIN coated drill defined and added in the control plan. | Mr. DattaPandhre | 27/07/2023 | 27/07/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | For TIN Coated Drill Initially 100% inspection will be done for parallelism to monitoring the results, after sustenance verification and joint discussion with ETL & SHARP inspection frequency will be changed . |
| Inspection Method | Sp. 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) |
CAP OIL LOCK (df) tool life defined for 500/sharpening but drill Ø14.10 worn out earlier than defined frequency. Dimensional variation found at end of the tool life after 500/sharpening. 511_Occurance_Before.pptx |
| Occurance (After) |
SS Tool life not getting as per defined so view of improvement in tool life in place of SS TIN (Titanium Nitride) coated drill is being used, SPC done for coated and non coated drill after process validation TIN coated drill defined and added in the control plan. Tool life defined 600/sharpening. 511_Occurance_After.pptx |
| Outflow (Before) |
100% inspection is not being done for parallelism. 511_Outflow_Before.pptx |
| Outflow (After) |
For TIN Coated Drill Initially 100% inspection will be done for parallelism to monitoring the results, after sustenance verification and joint discussion with ETL & SHARP inspection frequency will be changed . 511_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | HMSI(K86/K0LA) |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, ProcessFlowChart, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |