QFR No - 7001018333
Defect Details
| NC No. | 7001018333 |
| NC Date | 29/05/2024 |
| 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 | THICKNESS UNDERSIZE-End coil tip thickness undersize |
1. Problem Description
| Defect Description | End coil thickness found 0.5 mm against specification 0.8 mm (Min). |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 4000 |
| Is Defect Repeatative? | Yes |
| 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 |
8000
|
0
|
0
|
2000
|
0
|
10000
|
| Check Qty |
8000
|
0
|
0
|
2000
|
0
|
10000
|
| NG Qty |
4000
|
0
|
0
|
100
|
0
|
4100
|
| Scrap | 4100 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Scrap |
3. Process Flow
| Process Flow Description |
|---|
| COILING,TEMPRING,GRINDING.,SHOT PEENING ,2ND TEMPRING,WAVINESS |
4. Process Details
| Process / Operation | Grinding |
| Outsource | No |
| Machine / Cell | Grinding |
| Machine / Cell No. | Grinding Machine |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unksilled operator not set machine properly and check it properly result in togeneration of rejecti | Found operator deputed are well understood of grinidng process and deffect itcause 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 tapergrinding in some ca | Check the program used for grinding it was found OK | O |
| Method | Grinding angle more | Grinding angle found 300-350deg and tip thickness found less than 0.80 mm | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Sampling |
| 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 |
|---|---|---|---|---|---|
| Occurance | At grinding stage grinding angle will be maintained 320deg minimum to maintain tip thickness more than 0.80mm | VDP | 01/06/2024 | 01/06/2024 | Completed |
| Outflow | 100% Visual inspection started for grinding angle at grinding stage | 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 | sample Pla |
10. Evidance of Countermeasure
| Occurance (Before) |
Grinding Angle 300° to 350° 826_Occurance_Before.pdf |
| Occurance (After) |
Grinding Angle 320° minimum tip thickness more than 0.80 mm 826_Occurance_After.pdf |
| Outflow (Before) |
Sampling Inspection at Grinding stage 826_Outflow_Before.pdf |
| Outflow (After) |
100% Visual Inspection at Grinding stage 826_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | This action is applicable for this spring 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. |