QFR No - 7001010243
Defect Details
| NC No. | 7001010243 |
| NC Date | 01/05/2024 |
| NC Submission Date | |
| Part No. | 520KT00102 |
| Part Name | ROD BUSH |
| Supplier Name & Code | 100177-SPECIALITY SINTERED PRODUCTS P |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | PARALITY NOT OK.-Parallelism observed up to 0.150 against |
1. Problem Description
| Defect Description | Parallelism observed 0.150 against specification 0.100 mm. |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 15000 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | kalyan.babar@specialitysintered.com |
| Plant Head/CEO Email ID | Datta.gadhave@ssplpune.com |
| MD Email ID | lalit.chaudhari@ssplpune.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
51000
|
0
|
0
|
5000
|
0
|
56000
|
| Check Qty |
51000
|
0
|
0
|
5000
|
0
|
56000
|
| NG Qty |
51000
|
0
|
0
|
0
|
0
|
51000
|
| Scrap | 51000 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% inspection done for FG parts available at SSPL END |
3. Process Flow
| Process Flow Description |
|---|
| RM Inspection - Forming - Sintering - Debarring - Steam - Final inspection - Packaging |
4. Process Details
| Process / Operation | Forming |
| Outsource | Yes |
| Machine / Cell | 15F3 |
| Machine / Cell No. | 15F3 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | unskilled operator | interviewing operator operator skill observed ok | X |
| Material | Wrong grade RM used | verified Raw Materil TC obsered grade is OK | X |
| Material | incorrect resting material | verified resting obsevred less strength | O |
| Method | incorrect control plan | verified control plan flange tapper not addressed in control plan | O |
| Tool | incorrect tool used | verified inccorect tool used detected in first off | X |
| Method | incorrect inspection method | verified inspection method observed ok with V block & dial gauge | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | IS2500 |
7. Root Cause Analysis (Occurance)
| Why 1 | Parallelism NG observed up to 0.25 mm against spec 0.1 mm max |
| Why 2 | Parallelism Getting out of spec In Forming Process. |
| Why 3 | In Running Condition Length Taper Generated |
| Why 4 | Punch resting Getting Cracked during running condition |
| Why 5 | less strength of resting |
| Root Cause (Occurance) | less strength of resting |
Root Cause Analysis (Outflow)
| Why 1 | Parallelism NG observed up to 0.25 mm against spec 0.1 mm max |
| Why 2 | Part Not Detect in Process Inspection |
| Why 3 | Inspector Not Checked Flange Taper. |
| Why 4 | Flange Taper Checkpoint Not Address In Forming Control Plan. . |
| Why 5 | |
| Root Cause (Outflow) | Flange Taper Checkpoint Not Address In Forming Control Plan. . |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Countermeasure Details Responsibility Target Date Actual Date Status Occurance New Top Punch Resting Made With Sufficient Straight. (Total Width 50MM) Top Punch Resting Check Point Add In Tool History Card. | Mayur Patil | 16/05/2024 | 17/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | length inspection method changed flange tapper point added in forming control plan |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | IS2500 |
10. Evidance of Countermeasure
| Occurance (Before) |
N-31 material grade used 770_Occurance_Before.xlsx |
| Occurance (After) |
N-24 material grade used 770_Occurance_After.xlsx |
| Outflow (Before) |
Their was no check point of flange tapper 770_Outflow_Before.jpeg |
| Outflow (After) |
Flange tapper check point added in control plan 770_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | S2KT model |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Parallelism found Ok in upcoming fresh Lots . |