QFR No - 7000985442
Defect Details
| NC No. | 7000985442 |
| NC Date | 14/02/2024 |
| 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 | HOLE BLOCK-1.50 hole Problem |
1. Problem Description
| Defect Description | Hole block 1.50mm in Fork Pipe K0PG |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 170 |
| 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 |
3000
|
0
|
0
|
1300
|
500
|
4800
|
| Check Qty |
3000
|
0
|
0
|
1300
|
500
|
4800
|
| NG Qty |
170
|
0
|
0
|
0
|
0
|
170
|
| Scrap | 0 |
| Rework | 170 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% inspection done for Drill Hole 1.50 mm with Pin Gauge at customer end & In-house stock available. |
3. Process Flow
| Process Flow Description |
|---|
| RM - CNC MACHINING - DRILLING - DEBURRING - INSPECTION - BIN PACKING - DISPATCH. |
4. Process Details
| Process / Operation | DRILLING |
| Outsource | No |
| Machine / Cell | DRILLING MACHINE |
| Machine / Cell No. | DRILL MACHINE - 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Drill hole burr not cleaned | Verifed & found drill hole burr not getting removed from drill hole ID | X |
| Method | Deburring operation not done | Verified & observed deburring operation being done | O |
| Man | unskilled manpower | Verified record & found Skilled | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Deburring Process |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | HOLE BLOCK-1.50 hole Problem |
| Why 2 | Drill hole burr does not get removed in a deburring operation |
| Why 3 | generation of an excess hard burr at hole ID |
| Why 4 | Drill warn out before defined frequency of drill change |
| Why 5 | Drill bit Manufacturing defect |
| Root Cause (Occurance) | Drill bit Manufacturing defect |
Root Cause Analysis (Outflow)
| Why 1 | HOLE BLOCK-1.50 hole Problem |
| Why 2 | Drill hole burr does not get removed in a deburring operation |
| Why 3 | Drill hole burr not getting detected in Visual inspection |
| Why 4 | No Inspection Specified in the final Inspection Quality plan for the drill hole block |
| Why 5 | |
| Root Cause (Outflow) | No Inspection Specified in the final Inspection Quality plan for the drill hole block |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | check point added in Hourly inspection report for Drill hole block | Mr. Abhishek Yadav | 10/03/2024 | 08/03/2024 | Completed |
| Outflow | Inspection Specified in the final Inspection Quality plan for the drill hole block by using Pin gauge as per samplinug plan | Mr. Abhishek Yadav | 10/03/2024 | 08/03/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection Specified in the final Inspection Quality plan for the drill hole block by using Pin gauge as per samplinug plan |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | Sampleplan |
10. Evidance of Countermeasure
| Occurance (Before) |
No checkpoint added in Hourly inspection report for Drill hole block 677_Occurance_Before.pdf |
| Occurance (After) |
checkpoint added in Hourly inspection report for Drill hole block 677_Occurance_After.pdf |
| Outflow (Before) |
No Inspection was Specified in the final Inspection Quality plan for the drill hole block by using Pin gauge as per the sampling plan 677_Outflow_Before.pdf |
| Outflow (After) |
Inspection Specified in the final Inspection Quality plan for the drill hole block by using Pin gauge as per sampling plan 677_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | K86 |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | Quality Plan |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Hole block 1.5 mm in fork pipe K0PG. |