QFR No - 7001014527
Defect Details
| NC No. | 7001014527 |
| NC Date | 16/05/2024 |
| NC Submission Date | |
| Part No. | F2PH00902B |
| Part Name | VALVE RETAINER (C101B) |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | THICKNESS UNDERSIZE-Total Width undersize |
1. Problem Description
| Defect Description | Total width specified 9.30 mm found undersize 8.69 mm (NG). |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 4047 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@apw3.co.in |
| Plant Head/CEO Email ID | kurund.ma@sharp-engineers.com |
| MD Email ID | urkhandelwal@sharp-engineers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
70000
|
20000
|
6000
|
20000
|
10000
|
126000
|
| Check Qty |
70000
|
20000
|
6000
|
20000
|
10000
|
126000
|
| NG Qty |
14047
|
0
|
0
|
0
|
0
|
14047
|
| Scrap | 14047 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done at ETL Material and suspected material recalled for checking purpose. |
3. Process Flow
| Process Flow Description |
|---|
| 10) RM Inward 20) Parting 30) CNC 1st set up 40) OD grinding 50) Plating Process 60) Inward Inspection 70) Final Inspection 80) 90) Pre-dispatch Inspection10) Packing & Farwarding |
4. Process Details
| Process / Operation | CNC Process |
| Outsource | No |
| Machine / Cell | Machine Shop |
| Machine / Cell No. | SE/CNC/05 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Machine variation & inaccurate machine | JH/PM plan and execution being done as per requirement | O |
| Method | Wrong inspection medthod | Inspection similar for length checking by height checking gauge. | O |
| Tool | Tool/Insert worn out | Tool life monitoring as per defined frequency monitoring. | O |
| Man | Unskilled manpower | Unskilled manpower at final inspection stage | X |
| Material | Wrong material grade used | RM testing plan and execution as per plan available. | 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 | 1:1 |
7. Root Cause Analysis (Occurance)
| Why 1 | Dimension 9.30 u/s by 0.5mm |
| Why 2 | NG part mix up with ok part |
| Why 3 | NG material and OK material stored together. |
| Why 4 | Lack of storage |
| Why 5 | Construction on going for plant expansion. |
| Root Cause (Occurance) | NG material and OK material stored together. |
Root Cause Analysis (Outflow)
| Why 1 | DIM 9.30 under size part reached to ETL |
| Why 2 | Sampling Basis Inspection as per sampling plan IS:2500 |
| Why 3 | No 100% inspection done at FID stage |
| Why 4 | Inspection frequency define by system at PPAP stage |
| Why 5 | |
| Root Cause (Outflow) | Sampling Basis Inspection as per sampling plan IS:2500. No 100% inspection done at FID stage |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Red bins provided for NG material at final inspection and machining stage with key locking to avoid mix up issues. | Mr. Shaikh L.N. | 31/05/2024 | 31/05/2024 | Completed |
| Outflow | Sampling Basis Inspection as per sampling plan IS:2500 changed into 100% inspection at FID stage. Gauge provided for height checking. | Mr. Shaikh L.N. | 31/05/2024 | 31/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection at FID stage. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
NG material kept openly in the open bin 804_Occurance_Before.pptx |
| Occurance (After) |
Red bins provided for NG material at final inspection and machining stage with key locking to avoid mix up issues. 804_Occurance_After.pptx |
| Outflow (Before) |
Sampling Basis Inspection as per sampling plan IS:2500. No 100% inspection done at FID stage 804_Outflow_Before.jpg |
| Outflow (After) |
Sampling Basis Inspection as per sampling plan IS:2500 changed into 100% inspection at FID stage. Gauge provided for height checking. 804_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Total width specified 9.30 mm found undersize 8.69 mm after action taken at supplier end lot found Ok |