QFR No - 7000951769
Defect Details
| NC No. | 7000951769 |
| NC Date | 11/10/2023 |
| NC Submission Date | |
| Part No. | F1DZ00902B |
| Part Name | FORK BOLT K86A |
| Supplier Name & Code | 101037-SHREE PATEL INDUSTRIES |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | MATERIAL DEFECT-Material Defect on OD |
1. Problem Description
| Defect Description | Material defect found on head (OD) of fork bolt K86 |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 980 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | ekltmoemj1irgygxc21udo1u.jpg |
Supplier Communication Details
| Quality Head Email ID | quality_spi@rediffmail.com |
| Plant Head/CEO Email ID | planthead_spi@rediffmail.com |
| MD Email ID | rspatel_spi@rediffmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
6000
|
0
|
0
|
0
|
0
|
6000
|
| Check Qty |
6000
|
0
|
0
|
0
|
0
|
6000
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All suspected part checked and rejected part scraped. |
3. Process Flow
| Process Flow Description |
|---|
| 10.Incoming 20.Traub Turning 30.CNC 1st Setup 40.CNC 2nd Setup 50.Plating 60.Inspection 70.Packing & Dispatch |
4. Process Details
| Process / Operation | Incoming |
| Outsource | Yes |
| Machine / Cell | Incoming (INWARD) |
| Machine / Cell No. | RM INWARD |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Improper material handling | During genba visit, We found that input and output material are stored on difined location. | O |
| Machine | Power failure during operation | By verification power failure register, all the part between power failure are kept in hold area fo | O |
| Machine | Improper alignment of Machine | By verification of PM check sheet, Machine alignment found ok | O |
| Man | Unskilled manpower | Skill matrix verified and all the manpower found on required level 2 and level 3 | O |
| Material | NG incoming materia | During Gemba visit, We found all incoming material ok as per specification but visually damage. | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | VISUAL |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 25:1 |
7. Root Cause Analysis (Occurance)
| Why 1 | Defective part reached at custommer end. |
| Why 2 | This type of defect generated during CNC turning. |
| Why 3 | Operator not done visual Inspection during process. |
| Why 4 | Checking Frequency not defined. |
| Why 5 | |
| Root Cause (Occurance) | 1_ These Types of material defcet not visible during incoming inspection 2_These types of defect generated after CNC turning process But During process part not checked by Operator & Due to this defective part not captured during process . |
Root Cause Analysis (Outflow)
| Why 1 | Defective part reached at custommer end. |
| Why 2 | Part not captured during final inspection. |
| Why 3 | Inspector not aware about this type of defect. |
| Why 4 | Training not provided to inspector for related defect. |
| Why 5 | |
| Root Cause (Outflow) | Due to inspector lack of defect awarness. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Checking frequency define at machining during process. | Sanjay Lakhatariya | 15/10/2023 | 15/10/2023 | Completed |
| Outflow | Training provided to inspector for related defect. Defect sample displayed for better understanding | Sanjay Lakhatariya | 15/10/2023 | 15/10/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NO |
| 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) |
Control Plan 571_Occurance_Before.xlsx |
| Occurance (After) |
Control plan part checking frequency add in CNC 1st and CNC 2nd Turning. 571_Occurance_After.xlsx |
| Outflow (Before) |
Defect sample not displayed 571_Outflow_Before.jpeg |
| Outflow (After) |
Training provided to concern person 571_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Fork bolt K86A |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | TRAINING RECORD |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Material defect on head of fork bolt |