QFR No - 7001012537
Defect Details
| NC No. | 7001012537 |
| NC Date | 10/05/2024 |
| NC Submission Date | |
| Part No. | 550GN09102 |
| Part Name | MAIN SPRING-(HMS-30 & HMP-30) |
| Supplier Name & Code | 100186-SAGAR SPRINGS PRIVATE LIMITED |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | LENGTH OVERSIZE-Total Length 358.5 mm against 348.7 ±2mm |
1. Problem Description
| Defect Description | Total Length 358.5 mm against 348.7 ±2mm |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 306 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | 5zrawr3bwbr43c12lheq2hfv.jpg |
Supplier Communication Details
| Quality Head Email ID | quality@sagarsprings.com |
| Plant Head/CEO Email ID | ajai.singh@sagarsprings.com |
| MD Email ID | sagar@sagarsprings.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
13600
|
0
|
0
|
6000
|
0
|
19600
|
| Check Qty |
13600
|
0
|
0
|
6000
|
0
|
19600
|
| NG Qty |
306
|
0
|
0
|
2
|
0
|
308
|
| Scrap | 306 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100%inspection at ETL Halol plant |
3. Process Flow
| Process Flow Description |
|---|
| coiling, tempring, grinding, shot peening 2nd tempring, scragging, waviness, checking |
4. Process Details
| Process / Operation | Final inspection |
| Outsource | No |
| Machine / Cell | Final inspection |
| Machine / Cell No. | Final inspection |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Mix up of other part | Possibility of mix up of other model mix up next to tempering | O |
| Method | Inspection method for height checking wrong | Height checking of spring by checking gauge is found OK | O |
| Man | Operator negligance | No negligence found | O |
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 | Other model spring get mix at tempering stage |
| Why 2 | While line change over spring mix with existing spring |
| Why 3 | While line change over when furnace operator goes for material movement another model parts get drop |
| Why 4 | Small trolley used is not carry enough spring and there arise chance for mix up |
| Why 5 | |
| Root Cause (Occurance) | Method for using small trolley for material movement after tempering get filled quickly till operator empty tempered material to decided location, hence in case material get mixed at furnace where spare trolley is kept |
Root Cause Analysis (Outflow)
| Why 1 | Free length (mix up) is not checked at final oiling stage |
| Why 2 | Free length is checked 100% at waviness correction stage and spring get mix after it |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Model mix up is not check at final oiling stage |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Large bin will be kept at exit of furnace which avoid frequent transportation and could store more spring at time and operator could easily work on it while change over | Production-Supervisor | 12/05/2024 | 12/05/2024 | Completed |
| Outflow | 100% mix up is checked on final oiling stage by making spring stand vertical on plate | Packing - Crew | 12/05/2024 | 12/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Model mix up inspection started at final oiling-packing stage |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
While line change over when furnace operator goes for material movement another model parts get drop. Small trolley used is not carry enough spring and there arise chance for mix up 796_Occurance_Before.pdf |
| Occurance (After) |
Large bin will be kept at exit of furnace which avoid frequent transportation and could store more spring at time and operator could easily work on it while change over 796_Occurance_After.pdf |
| Outflow (Before) |
Free length (mix up) is not checked at final oiling stage 796_Outflow_Before.pdf |
| Outflow (After) |
100% mix up is checked on final oiling stage by making spring stand vertical on plate. 796_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All long and slender Main spring |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |