QFR No - 7000951326
Defect Details
| NC No. | 7000951326 |
| NC Date | 09/10/2023 |
| NC Submission Date | |
| Part No. | F2HL00402B |
| Part Name | OIL LOCK COLLAR (HMC-31/K38G) |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | MIX UP OTHER MODEL-Wrong part |
1. Problem Description
| Defect Description | Other model mixing parts found in oil lock collar |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 123 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | ekltmoemj1irgygxc21udo1u.jpg |
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 |
6000
|
5000
|
5000
|
10000
|
5000
|
31000
|
| Check Qty |
6000
|
5000
|
5000
|
10000
|
5000
|
31000
|
| NG Qty |
123
|
0
|
0
|
0
|
0
|
123
|
| Scrap | 0 |
| Rework | 123 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All the suspected material has been cross checked and dispatched. |
3. Process Flow
| Process Flow Description |
|---|
| 10) RM Inward 20) RM Storage 30) Parting & Chamfering 40) ID Chamfering 50) OD grinding 60) Plating (Outsource) 70) 80) Inward Inspection 90) Final Inspection 100) Packing & Dispatch |
4. Process Details
| Process / Operation | Packing |
| Outsource | No |
| Machine / Cell | Final Inspection |
| Machine / Cell No. | Q Gate |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Operator Working Method Wrong | SOP/WI available on machine and operator aware about it and being followed. | O |
| Man | Un-skilled Operator | Stage wise skill matrix and operator license are not evident as per F/HR/06 | X |
| Material | Incorrect RM grade | Third part inspection verified for chemical composition and hardness testing as per requirement. | O |
| Tool | Tool life monitoring inadequate | Tool life for all the tool i.e. forming tool, drill, and insert are defined and recorded as per freq | O |
| Machine | Improper preventive maintenance | Preventive maintenance plan evident as per P/MNT/01 and being followed as per F/MNT/07 | O |
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 | Bag To Bag |
7. Root Cause Analysis (Occurance)
| Why 1 | Wrong Part reached at ETL |
| Why 2 | Two different part kept at same location. |
| Why 3 | Packing was same. |
| Why 4 | Not detected from outside. |
| Why 5 | Transparent poly bag not in used. |
| Root Cause (Occurance) | Transparent poly bag not in used at BSR stage. |
Root Cause Analysis (Outflow)
| Why 1 | Wrong Part reached at ETL |
| Why 2 | Incorrect material selection form BSR while dispatching. |
| Why 3 | Person not aware about the part |
| Why 4 | SOP & Analysis: Material handling of Finish Product being supplied to Endurance not displayed at BSR. |
| Why 5 | |
| Root Cause (Outflow) | SOP & Analysis: Material handling of Finish Product being supplied to Endurance not displayed at BSR. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Transparent poly bag are being used at BSR stage. | Mr. Ganesh Mande | 17/10/2023 | 17/10/2023 | Completed |
| Outflow | SOP & Analysis: Material handling of Finish Product being supplied to Endurance displayed at BSR. | Mr. Ganesh Mande | 17/10/2023 | 17/10/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100%inspection |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
Transparent poly bag not in used at BSR stage. 573_Occurance_Before.pptx |
| Occurance (After) |
Transparent poly bag are being used at BSR stage. 573_Occurance_After.pptx |
| Outflow (Before) |
SOP & Analysis: Material handling of Finish Product being supplied to Endurance not displayed at BSR. 573_Outflow_Before.pptx |
| Outflow (After) |
SOP & Analysis: Material handling of Finish Product being supplied to Endurance displayed at BSR. 573_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | PFMEA, WISOP, PackingStd |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Wrong model (Mix up other model) |