QFR No - 7000985666
Defect Details
| NC No. | 7000985666 |
| NC Date | 14/02/2024 |
| 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 | LENGTH UNDERSIZE-(Short length) |
1. Problem Description
| Defect Description | Length undersize 287.89 mm against specification 288.3+0.2/-0.2. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 215 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | SushantJadhav@tii.murugappa.com |
| Plant Head/CEO Email ID | BhatnagarS@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
|
1500
|
0
|
4000
|
| Check Qty |
2500
|
0
|
0
|
1500
|
0
|
4000
|
| NG Qty |
215
|
0
|
0
|
12
|
0
|
227
|
| Scrap | 227 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% inspection done for Tube Total Length on Height Gauge. |
3. Process Flow
| Process Flow Description |
|---|
| RM - CNC MACHINING - DRILLING - Deburring - Inspection - Bin Packing - Dispatch. |
4. Process Details
| Process / Operation | CNC Machining |
| Outsource | No |
| Machine / Cell | CNC Machineing |
| Machine / Cell No. | cell No-3 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Raw tube OD U/s | Verified Records & found ok | O |
| Man | Tube come back due to Back Pressure | Verified through Gamba &found Tube come back due to Back Pressure. Operator has to Judge for resting | X |
| Man | SOP not Followed | Verified through Gemba observation and found Operator has followed the SOP. | O |
| Machine | Machine Parameter | Verified through Gemba observation and found all Machine Parameter as per Control Plan | O |
| Method | Wrong Setup | Verified Setup Repots & found OK. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Pokayoke |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10 Nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Length under size found at customer end |
| Why 2 | Excess Material cut during Tube facing operation in CNC Machining. |
| Why 3 | Tube hold away from Stopper. |
| Why 4 | Tube come back due to Back Pressure. Operator has to Judge for resting on Stopper. |
| Why 5 | Low awareness of Operator. |
| Root Cause (Occurance) | Low awareness of Operator for proper Tube resting on Stopper. |
Root Cause Analysis (Outflow)
| Why 1 | Length under size found at customer end |
| Why 2 | Short length not detected By Sensor on Drilling M/c |
| Why 3 | Drilling Fixture Poka -Yoke Senor Malfunction. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Drilling Fixture Poka -Yoke Senor Malfunction. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | In Final Inspection added for 100 % Inspection with Conventional Length Gauge for Next 3 Months | Mr. Palak Shah | 28/02/2024 | 08/03/2024 | Completed |
| Occurance | Training given to Operator for How to butting the Tube so Tube will not come Back from Stopper. | Mr. Abishek Yadav | 27/02/2024 | 08/03/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | In Final Inspection added for 100 % Inspection with Conventional Length Gauge for Next 3 Month. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Low awareness to the Operator regarding proper Tube resting on the Stopper. 678_Occurance_Before.pdf |
| Occurance (After) |
awareness to the Operator regarding proper Tube resting on the Stopper. 678_Occurance_After.pdf |
| Outflow (Before) |
Drilling Fixture Poka -Yoke Sensor Malfunction. 678_Outflow_Before.pdf |
| Outflow (After) |
In addition to the Existing poka yoke, the Length inspection started
on length Gauge & Started the 100% Length Verification with Length gauge. 678_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | K86 |
12. Document Review
| Documents | |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Total length undersize problem in fork pipe K86 |