QFR No - 7000984362
Defect Details
| NC No. | 7000984362 |
| NC Date | 10/02/2024 |
| NC Submission Date | |
| Part No. | F1FA01333M |
| Part Name | FORK PIPE MACHINED-K86A |
| Supplier Name & Code | 101109-TUBE INVESTMENTS OF INDIA LIMI |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | RUSTY-Rust material |
1. Problem Description
| Defect Description | Rusty Fork Pipe OD |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 472 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | anandms@tii.murugappa.com |
| Plant Head/CEO Email ID | girisha@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 |
2500
|
0
|
0
|
1000
|
8200
|
11700
|
| Check Qty |
2500
|
0
|
0
|
1000
|
8200
|
11700
|
| NG Qty |
472
|
0
|
0
|
23
|
2900
|
3395
|
| Scrap | 0 |
| Rework | 3395 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% visual inspection done for Rust on Machined Area at customer end & In- House end. |
3. Process Flow
| Process Flow Description |
|---|
| RM - CNC MACHINING - DRILLING - DEBURRING - FINAL INSPECTION - BIN PACKING - DISPATCH. |
4. Process Details
| Process / Operation | CNC MACHINING & INSPECTION |
| Outsource | No |
| Machine / Cell | CNC MACHINING |
| Machine / Cell No. | CELL NO - 5 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | RM in rusty Condition | Verified the Inward Records & no Rusty RM Reciept evident | X |
| Machine | Coolant Concentration % not Adhequete | Coolant Concentration % cheched & found not Wthin Specification | O |
| Man | Operator Skill | Verified & observed skilled operatoer availibility | 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 | Sampleplan |
7. Root Cause Analysis (Occurance)
| Why 1 | Fork pipe OD observed Rusty |
| Why 2 | Coolant Concentration %, not Adhequete |
| Why 3 | Coolant Concentration % preparation done by using the wrong inspection method |
| Why 4 | Lack of awareness regarding the use of Refactrometer |
| Why 5 | |
| Root Cause (Occurance) | Lack of awareness regarding the use of Refactrometer. |
Root Cause Analysis (Outflow)
| Why 1 | Fork pipe OD observed Rusty |
| Why 2 | Not detected during the Final Inspection |
| Why 3 | Lack of awareness to the final inspector regarding the rust issue in the machined tubes supplies |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Lack of awareness to the final inspector regarding the rust issue in the machined tube supplies |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Arabian rust Coat RPO Oil application started | Mr. Palak Shah | 08/03/2024 | 08/03/2024 | Completed |
| Outflow | Awareness training given to the final inspector regarding the rust issue in the machined tube supplies | Mr. Anaand Nagare | 10/03/2024 | 08/03/2024 | Completed |
| Occurance | Authorized person for coolant prepation identified & Supervisory level approval defined | Mr. Omkar Wagale | 10/03/2024 | 08/03/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % Inspection to be done for the rusty Issue |
| 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) |
No Authorized person for coolant preparation was identified & No Supervisory-level approval was defined 675_Occurance_Before.pdf |
| Occurance (After) |
Authorized person for coolant prepation identified & Supervisory level approval defined 675_Occurance_After.pdf |
| Outflow (Before) |
No Awareness to the final inspector regarding the rust issue in the machined tube supplies & WI for RPO Application 675_Outflow_Before.pdf |
| Outflow (After) |
Awareness training given to the final inspector regarding the rust issue in the machined tube supplies 675_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | K0PG |
12. Document Review
| Documents | WISOP |
| Specify Other Document | WI & Authorization |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Rust problem in fork pipe K0PG |