QFR No - 7000951785
Defect Details
| NC No. | 7000951785 |
| NC Date | 11/10/2023 |
| NC Submission Date | |
| Part No. | F1DZ00902B |
| Part Name | FORK BOLT K86A |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | FITTMENT NOT OK.-Wrong part |
1. Problem Description
| Defect Description | Fork bolt K86 found other model / wrong parts . |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 272 |
| Is Defect Repeatative? | No |
| 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 |
1440
|
7200
|
0
|
2000
|
1400
|
12040
|
| Check Qty |
1440
|
7200
|
0
|
2000
|
1400
|
12040
|
| NG Qty |
272
|
0
|
0
|
0
|
0
|
272
|
| Scrap | 272 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material at ETL end ,warehouse and inhouse checked and verify. |
3. Process Flow
| Process Flow Description |
|---|
| 10) RM INWARD 20) RM STORAGE 30) TRAUB PARTING AND DRILLING 40) GRINDING 50)MILLING 60) CNC LATHE TURNING 70) ROLLING 80) PLATING 90) PLATING INWARD 100) FINAL INSPECTION 110) PRE DISPATCH INSPECTION 120) PACKING AND DISPATCH. |
4. Process Details
| Process / Operation | Storage (Warehouse) |
| Outsource | Yes |
| Machine / Cell | NA |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Raw material is not as per required specifications. | Verify the raw material as per required size and grade found ok. | O |
| Machine | Machining not done as per process sequence. | Process flow verified as per required sequence and process flow found ok. | O |
| Method | Material handling at Warehouse. | Material mixup at the time of dispatch from warehouse to ETL. | X |
| Man | Un-skilled operator | Verify the stagewise skill matrix and found ok | O |
| Tool | Tool wear out before as required life. | Tool life as per required frequency monitoring found ok. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Warehouse Storage. |
| 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 found with fork bolt K86. |
| Why 2 | Material unknowingly dispatch with required parts. |
| Why 3 | Packed material lying near each other. |
| Why 4 | Packing person dont know the difference between the both parts. |
| Why 5 | unskilled packing person at warehouse. |
| Root Cause (Occurance) | Unskilled packing person at warehouse. |
Root Cause Analysis (Outflow)
| Why 1 | Wrong part found with fork bolt K86. |
| Why 2 | Incorrect material selection for the dispatch to ETL. |
| Why 3 | Person not aware about the parts. |
| Why 4 | Same colour identification tag on packing box for both parts. |
| Why 5 | |
| Root Cause (Outflow) | Same colour identification tag on packing box for both parts. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | OPL display at warehouse for part identification and packing identification tag. | Mr. Jagdish Ninayade | 23/10/2023 | 24/10/2023 | Completed |
| Occurance | Packing material identification tag on the box will be change as per ETL Plant. | Mr.Yogesh Sonune | 23/10/2023 | 30/10/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % inspection at dispatch stage and also at warehouse location. |
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | No |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | bag to bag |
10. Evidance of Countermeasure
| Occurance (Before) |
No any material part visualization display at warehouse storage of Transporter. 570_Occurance_Before.xlsx |
| Occurance (After) |
One point lesson given to warehouse person about part visualization. 570_Occurance_After.ppt |
| Outflow (Before) |
Both parts of ETL plant having same colour identification tag on the packing box. 570_Outflow_Before.xlsx |
| Outflow (After) |
Colour identification change from Yellow identification tag to White identification tag. 570_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | PackingStd |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Wrong parts (fitment not OK) |