QFR No - 7001014528
Defect Details
| NC No. | 7001014528 |
| NC Date | 16/05/2024 |
| NC Submission Date | |
| Part No. | F1GN01102B |
| Part Name | MAIN SPRING K86A |
| Supplier Name & Code | 100186-SAGAR SPRINGS PRIVATE LIMITED |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | DIMN.U/SIZE.-Tip thickness undersize. |
1. Problem Description
| Defect Description | Tip thickness specified 0.8 mm min observation 0.20 mm (NG) |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 1020 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
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 |
4080
|
0
|
4500
|
0
|
0
|
8580
|
| Check Qty |
4080
|
0
|
4500
|
0
|
0
|
8580
|
| NG Qty |
1020
|
0
|
250
|
0
|
0
|
1270
|
| Scrap | 20 |
| 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,WAVINESS |
4. Process Details
| Process / Operation | Grinding stage |
| Outsource | No |
| Machine / Cell | Grinding |
| Machine / Cell No. | Grinding |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unksilled operator not set machine properly and check it properly result in to generation of rejecti | Found operator deputed are well understood of grinidng process and deffect it cause and counter meas | O |
| Material | Wrong grade wheel result on grinding performance | Check the grade of wheel used ie ceramic wheel | O |
| Method | Faulty program will result into more feed, full grinding, less grinding or taper grinding in some ca | Check the program used for grinding it was found OK | O |
| Method | Grinding angle more | Grinding angle found 300 to 350deg and tip thickness found less than 0.80 mm | 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 | Sample pla |
7. Root Cause Analysis (Occurance)
| Why 1 | Grinding angle more |
| Why 2 | Grinding angle measures 300° to 350° against specification 320° minimum |
| Why 3 | Grinding angle maintained at higher band causing thickness less |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Grinding angle maintained at higher band (300° to 350°) causing thickness less |
Root Cause Analysis (Outflow)
| Why 1 | Tip thickness less |
| Why 2 | Inspection done on sampling basis |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspection done on sampling basis |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 100% Visual inspection started for grinding angle at grinding stage | VDP | 01/06/2024 | 01/06/2024 | Completed |
| Occurance | At grinding stage grinding angle will be maintained 320 deg minimum | VDP | 01/06/2024 | 01/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No change |
| Inspection Method | Other |
| Other Inspection Method | 100% Visual inspecti |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10 no/1000 |
10. Evidance of Countermeasure
| Occurance (Before) |
At Grinding stage Grinding angle maintained 300° to 350° 805_Occurance_Before.pdf |
| Occurance (After) |
At Grinding stage Grinding angle maintained 320° deg minimum to maintain tip thickness 0.80 mm. 805_Occurance_After.pdf |
| Outflow (Before) |
Inspection on sampling basis. 805_Outflow_Before.pdf |
| Outflow (After) |
100% Inspection for Grinding angle at Grinding stage. 805_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Action applicable for this part only. |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | In-process Inspectio |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Tip thickness found less against specified 0.8 mm min. |