QFR No - 7001013621
Defect Details
| NC No. | 7001013621 |
| NC Date | 14/05/2024 |
| NC Submission Date | |
| Part No. | S2CW00612B |
| Part Name | D NUT- HF DELUX |
| Supplier Name & Code | 100151-EXCELL PRESSINGS |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | NOT AS PER SPECIFICATION-perpendicularity 0.66 mm against 0.25 mm |
1. Problem Description
| Defect Description | Not as per Specification Perpendicularity 0.66 mm against 0.25 mm. |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 4000 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | excellpressings.qc@gmail.com |
| Plant Head/CEO Email ID | yogesh_vaidya42@yahoo.co.in |
| MD Email ID | excellpressings@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
4000
|
0
|
0
|
2000
|
3000
|
9000
|
| Check Qty |
4000
|
0
|
0
|
2000
|
3000
|
9000
|
| NG Qty |
4000
|
0
|
0
|
1200
|
800
|
6000
|
| Scrap | 6000 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| We have checked all the lots available in Finished goods area and parts available in Work in progress, in which some parts are found NG, that will be scraped. |
3. Process Flow
| Process Flow Description |
|---|
| Shearing -Blanking & piercing - ID chamfer- tapping to ID(M9X1.25 6G)-plating-final inspection- dispatch |
4. Process Details
| Process / Operation | Tapping opeartion |
| Outsource | No |
| Machine / Cell | Tapping machine upto M12 |
| Machine / Cell No. | EP-25 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | STOPPER STRIP WEAR OUT | STOPPER STRIP FOUND WEAR OUT | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | Perpendicularity increased |
| Why 2 | Threading has gone crossed while tapping |
| Why 3 | Part has moved with tap to upper side,part got tilt by 0.3 mm. |
| Why 4 | Stopper strip provided on tapping fixture has wear out |
| Why 5 | Not checked the stopper strip |
| Root Cause (Occurance) | As the stopper strip was wear out, part came on top side and part get tilted, so perpendicularity increased. |
Root Cause Analysis (Outflow)
| Why 1 | Part not checked for perpendicularity |
| Why 2 | not aware of problem raised due to perpendicularity |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Perpendicularity was not checked in process and final inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | part will be checked in process inspection and in final inspection for perpendicularity | Ankosh Mathure | 18/05/2024 | 18/05/2024 | Completed |
| Occurance | stopper strip will be changed | Ankosh Mathure | 18/05/2024 | 18/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | perpendicularity will be checked for every lot |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
10. Evidance of Countermeasure
| Occurance (Before) |
STOPPER STRIP ON TAPPING FIXTURE WEAR OT 802_Occurance_Before.jpg |
| Occurance (After) |
NEW STOPPER STRIP OF HARDENED MATERIAL USED 802_Occurance_After.jpg |
| Outflow (Before) |
PERPENDICULARITY FOUND NOT OK 802_Outflow_Before.jpg |
| Outflow (After) |
PERPENDICULARITY OBSERVED OK 802_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | TAPPING MACHINE EP-17 |
12. Document Review
| Documents | PMCheckSheet, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |