QFR No - 7000952518
Defect Details
| NC No. | 7000952518 |
| NC Date | 14/10/2023 |
| NC Submission Date | |
| Part No. | F2FA19033M |
| Part Name | K0PG FORK PIPE MACHINED |
| Supplier Name & Code | 101109-TUBE INVESTMENTS OF INDIA LIMI |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | DENT ON FACE-Dent on Face,Rusty,Ring mark ,Other part |
1. Problem Description
| Defect Description | Dent of face of Fork pipe K0PG |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 47 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | boyp50s1ep5zxm1shntow0gh.jpg |
Supplier Communication Details
| Quality Head Email ID | anandms@tii.murugappa.com |
| Plant Head/CEO Email ID | vijayakumarv@tii.murugappa.com |
| MD Email ID | mukeshahuja@tii.murugappa.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
9500
|
0
|
0
|
4000
|
5000
|
18500
|
| Check Qty |
9500
|
0
|
0
|
4000
|
5000
|
18500
|
| NG Qty |
47
|
0
|
0
|
0
|
0
|
47
|
| Scrap | 47 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Re-verification done through Visual Inspection of all available material at ETL end & in FG & WIP material with Identification Mark. |
3. Process Flow
| Process Flow Description |
|---|
| RM Inward - Storage - CNC Machining - Drilling - Deburring - Inspection - Bin Packing - Dispatch. |
4. Process Details
| Process / Operation | WIP Material Storage |
| Outsource | No |
| Machine / Cell | Trollys |
| Machine / Cell No. | Trolly |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Compresser Air Dryer Not working | Verified & found in not working condition. | X |
| Material | In coming Raw tube Rusty & dent damage | Verified & found OK | O |
| Man | SOP not Followed | Verified through Gemba observation and found Operator has followed the SOP. | O |
| Machine | Machining Parameter | Verified through Gemba observation and found all Machine Parameter as per Control Plan | O |
| Method | Coolant concentration | Verified through Gemba observation and found Coolant concentration 3 - 4%. | X |
| Man | Material falls from Bins. | Verified & found that in dispatch Vehicle stacking bin Height is high.t | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | K0PG FORK PIPE MACHINED found Rusty & dent Mark on Machined Area at customer end. |
| Why 2 | 1.rust generated on Machined area after CNC machining process 2.Water comes in contact through compressed air in cleaning Operation. |
| Why 3 | 1.due to Less coolant concentration used in CNC machine rust get formed on machined area .2. Compressor Air Dryer Not working Condition. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | 1. Less coolant concentration used in CNC machine , 2. Compressor Air Dryer Not working Condition. |
Root Cause Analysis (Outflow)
| Why 1 | K0PG FORK PIPE MACHINED found Rusty & dent Mark on Machined Area at customer end. |
| Why 2 | Part not capture in final 100 % Visual Inspection |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Visual Inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Coolant concentration increased to 5-6 % from 3 - 4% | Mr. Palak Shah | 16/10/2023 | 16/10/2023 | Completed |
| Occurance | Air Dryer repaired & now in working condition | Mr. Palak Shah | 16/10/2023 | 16/10/2023 | Completed |
| Outflow | Training given to Operators & Final inspector for inspection of Rust & dent mark on Machined area | Mr. Anand Nagare | 16/10/2023 | 16/10/2023 | Completed |
| Occurance | Bin Stacking height in Dispatch Vehicle is defined. | Mr. Palak Shah | 17/10/2023 | 17/10/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | 100 %Visual Inspection |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
1. due to Less coolant (3-4%)concentration used in CNC machine rust get formed on machined area 2.Water comes in contact through compressed air in cleaning Operation due to Air Dryer Not Working.3.Over Stacking of bins in vehicle bins can falls in loading & unloading material cause dent & damage on Machining Area. 584_Occurance_Before.pptx |
| Occurance (After) |
1. Coolant concentration increased to 5-6 % from 3 - 4%.
2. Compressor Air dryer repaired & in working condition .
3.Stacking position define (Red color marking for maximum stacking of material ) 584_Occurance_After.pptx |
| Outflow (Before) |
Part not capture in final 100 % Visual Inspection 584_Outflow_Before.pdf |
| Outflow (After) |
Training given to Inspector for Visual Inspection for Rust & Dent & Damage 584_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | FORK PIPEMACHINED K86 / Sanand |
12. Document Review
| Documents | |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Rust and dent in fork pipe |