QFR No - 7001005905
Defect Details
| NC No. | 7001005905 |
| NC Date | 15/04/2024 |
| NC Submission Date | |
| Part No. | 53BKZ00102 |
| Part Name | RUBBER BUSH |
| Supplier Name & Code | 101023-FORES ELASTOMECH INDIA PVT. LT |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | DIMETER UNDERSIZE-Outer dia undersize |
1. Problem Description
| Defect Description | OD found undersize 23.637 mm against specification 24.3+0.3/-0.3 mm |
| Detection Stage | Customer End |
| Problem Severity | Fitment |
| NG Quantity | 10000 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | malani.pritam@foresgroup.com |
| Plant Head/CEO Email ID | singh.barinder@foresgroup.com |
| MD Email ID | swamy.pj@foresgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
17500
|
0
|
7500
|
0
|
0
|
25000
|
| Check Qty |
17500
|
0
|
7500
|
0
|
0
|
25000
|
| NG Qty |
20
|
0
|
0
|
0
|
0
|
20
|
| Scrap | 20 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % inspection by ring gauge at final Inspection & dot marking provided on parts 100% |
3. Process Flow
| Process Flow Description |
|---|
| Inward material- Mixing - Moulding- Buffing process- Final Inspection |
4. Process Details
| Process / Operation | Buffing process |
| Outsource | No |
| Machine / Cell | Machine no-01 |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Tool design not okay | OD maintained in Tool is 24.20 | X |
| Method | Inspection on sampling basis | Skipped from inspection | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
7. Root Cause Analysis (Occurance)
| Why 1 | OD undersize |
| Why 2 | OD undersize on parting line |
| Why 3 | OD undersize due to buffing process at parting line |
| Why 4 | OD dimension got undersize due to excess buffing process. |
| Why 5 | |
| Root Cause (Occurance) | OD dimension got undersize due to excess buffing process. |
Root Cause Analysis (Outflow)
| Why 1 | OD undersize |
| Why 2 | Skipped from Inspection |
| Why 3 | Inspection as per sampling |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspection as per sampling |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1)Training Given to buffing operator 2)OPL display at work station 3)Work Instruction updated 4)Frequency of inspection increases from 2 hourly to 1 hourly | Buffing process InCharge | 16/04/2024 | 16/04/2024 | Completed |
| Occurance | Dimension of OD in Mould will be maintained 24.5 mm | Fores | 26/04/2024 | 26/04/2024 | Completed |
| Outflow | 1)Training given to inspector 2)Q Alert displayed 3)Defective sample & limit sample to displayed 4)Dot marking started after inspection 5)OD inspection by Ring gauge 100 % | Final Inspection | 16/04/2024 | 16/04/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection by ring gauge |
| 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) |
Excess buffing 749_Occurance_Before.jpg |
| Occurance (After) |
Training record of buffing operator 749_Occurance_After.pdf |
| Outflow (Before) |
Inspection on sampling 749_Outflow_Before.jpg |
| Outflow (After) |
Training record of Final inspector 749_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | Work instruction |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Tool OD modified from 24.2 to higher tolerance side 24.5 mm in die . No Ng parts found in fresh upcoming lots . |