QFR No - 7001010242
Defect Details
| NC No. | 7001010242 |
| NC Date | 01/05/2024 |
| 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 | RUN OUT MORE-ID Runout NG and Bend Part |
1. Problem Description
| Defect Description | Fork pipe straightness was Observed 0.150 ~0.200 mm against specification 0.06/200 mm. Runout observed was 0.150~0.180 mm against specification 0.08 B. |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 765 |
| Is Defect Repeatative? | No |
| 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
|
1500
|
28000
|
32500
|
| Check Qty |
3000
|
0
|
0
|
1500
|
28000
|
32500
|
| NG Qty |
765
|
0
|
0
|
5
|
35
|
805
|
| Scrap | 805 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% inspection after Rough Grinding at ETL end & 100 % Visual Inspection for Tube Machining OD Chamfer at Final Inspection & Sampling Inspection on Fixture with Dial stand & magnetic Block at Sanand Machining center. |
3. Process Flow
| Process Flow Description |
|---|
| TUBE FORMING - ANNEALING - WET PROCESS - PUSH POINTING - DRAWING - STRESS RELIEVING - STRAIGHTENING - ECT - CTL - FACING & CHAMFERING - FINAL INSPECTION - PACKING |
4. Process Details
| Process / Operation | STRAIGHTENING |
| Outsource | No |
| Machine / Cell | TFF straightening machine |
| Machine / Cell No. | TFF straightening mc |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Operator failed to inspect | Auto counted inspected part is match with packed qty so, there is no possibility of failure. | O |
| Machine | Straightening roll damage | Roll condition verified , no mark observed & no roll change activity done. | O |
| Tool | Checking instrument Error | Calibrated instrument used & the least count 0.01mm so, there is no possibility of instrument error. | O |
| Method | Gauge checking Method Error | Ok & NG part checked in existing checking method- Arrived KAPPA is 0.40 so, present checking method | X |
| Machine | Straightening pressure roll reversed | Straightening pressure roll bit reversed while straightening process. | 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 | Fork pipe straightness was Observed 0.150 ~0.200 mm against specification 0.06/200 mm. |
| Why 2 | Straightening pressure roll reversed |
| Why 3 | Straightening Pressure roll partially loosen |
| Why 4 | Pressure roll clamping inherent seal loosened while operation |
| Why 5 | Operator failed lock the inherent seal once in a week. |
| Root Cause (Occurance) | Operator failed lock the inherent seal once in a week. |
Root Cause Analysis (Outflow)
| Why 1 | Fork pipe straightness was Observed 0.150 ~0.200 mm against specification 0.06/200 mm. |
| Why 2 | Gauge checking Method Error. |
| Why 3 | Arrived KAPPA is 0.40 after attribute MSA. |
| Why 4 | NG parts are accepted by all appraiser |
| Why 5 | Present run out rest spot & dial indicator not detected corner run out. |
| Root Cause (Outflow) | Present run out rest spot & dial indicator not detected corner run out. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Additional one dial indicator added at the both end corner of tube to checking run out. | Mr. Satish | 08/05/2024 | 04/05/2024 | Completed |
| Occurance | Roll locking mechanism additionally provided outer side of roll adjustment handle. | Mr. Satish. | 13/05/2024 | 08/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Additional one dial indicator added at the both end corner of tube to checking run out. |
| 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) |
Roll locking mechanism not available to roll adjustment handle. 771_Occurance_Before.pptx |
| Occurance (After) |
Roll locking mechanism additionally provided outer side of roll adjustment handle. 771_Occurance_After.pptx |
| Outflow (Before) |
Bend checking with Dial indicator at middle only. 771_Outflow_Before.pptx |
| Outflow (After) |
Three dial indicator , especially added one dial at both end of tube to check tube corner bend also 771_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Action to be implemented between 280 mm to 305 mm cut length. |
12. Document Review
| Documents | WISOP |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |