QFR No - 7001019734
Defect Details
| NC No. | 7001019734 |
| NC Date | 01/06/2024 |
| 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 | HIGHT U/SIZE.-Total Width undersize |
1. Problem Description
| Defect Description | Total width undersize, Specification 9.3 mm observation 8.75 mm |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 4670 |
| 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 |
10000
|
0
|
5000
|
0
|
10000
|
25000
|
| Check Qty |
10000
|
0
|
5000
|
0
|
10000
|
25000
|
| NG Qty |
4670
|
0
|
0
|
0
|
0
|
4670
|
| Scrap | 4670 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done for all the suspected material of pipeline and defective part removed from OK part and quarantine. |
3. Process Flow
| Process Flow Description |
|---|
| 10) RM inward 20) RM Storage 30) Parting 40) CNC 1st set up 50) OD grinding 60) Plating (Outsource) 70) Inward Inspection 80) Final inspection 90) Pr-dispatch inspection 100) Packing & forwarding. |
4. Process Details
| Process / Operation | CNC Machining |
| Outsource | No |
| Machine / Cell | Machine Shop |
| Machine / Cell No. | SE/CNC 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled manpower | Skilled manpower available | O |
| Tool | Tool/Insert worn out | Tool life monitoring as per defined frequency available in the machine interlock. | O |
| Machine | Machine Variation | JH/PM as per defined frequency | O |
| Material | Suspected NG part in the pipeline material | Pipeline material was NG and not recalled after receipt of customer complaint | X |
| Method | Incorrect checking method | common method for inspection by attribute type height gauge | 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 | Total length under part reached at ETL |
| Why 2 | NG material of pipeline not recalled |
| Why 3 | Because of line stoppage |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | NG material of pipeline not recalled |
Root Cause Analysis (Outflow)
| Why 1 | Total length under part reached at ETL |
| Why 2 | not detected in the final inspection |
| Why 3 | Taper observed at one side of the parts |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Taper observed at one side of the parts |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Inventory level of ware house for VALVE RETAINER increase as per defined scheduled qty | Mr. Kurund M.A. | 20/06/2024 | 20/06/2024 | Completed |
| Outflow | Part are being checked at both side of the part by attribute type height gauge 100% before dispatch. inspector identification tag are being provided for traceability purpose | Mr. Shaikh L.N | 20/06/2024 | 20/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Component are being checked at both side of the part by attribute type height gauge 100% before dispatch. |
| 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 of pipeline not recalled because of less material inventory level at warehouse. 833_Occurance_Before.pptx |
| Occurance (After) |
Inventory level of ware house for VALVE RETAINER increase as per defined scheduled qty. 833_Occurance_After.xlsx |
| Outflow (Before) |
Taper observed at one side of the parts, inspection done only one side of the part. 833_Outflow_Before.pptx |
| Outflow (After) |
Part are being checked at both side of the part by attribute type height gauge 100% before dispatch. inspector identification tag are being provided for traceability purpose 833_Outflow_After.pptx |
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 undersize |