QFR No - 7001024806
Defect Details
| NC No. | 7001024806 |
| NC Date | 18/06/2024 |
| NC Submission Date | |
| Part No. | S2DP02902B |
| Part Name | EXTENSION K55G |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | CRACK-crack lot (suspected material ) |
1. Problem Description
| Defect Description | Crack |
| Detection Stage | Inprocess |
| Problem Severity | Safety |
| NG Quantity | 2200 |
| 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 |
5000
|
5000
|
2000
|
3000
|
500
|
15500
|
| Check Qty |
5000
|
5000
|
2000
|
3000
|
500
|
15500
|
| NG Qty |
2200
|
0
|
0
|
0
|
5
|
2205
|
| Scrap | 2205 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done immediately for suspected material of pipeline . |
3. Process Flow
| Process Flow Description |
|---|
| 10) RM Inward 20) RM Storage 30) Traub Operation ( Parting & Drilling) 40) Forming 50) Tapping 60) OD grinding 70) MPI 80) Visual Inspection 90) Oiling 100) Packing & forwarding |
4. Process Details
| Process / Operation | Traub Machining |
| Outsource | No |
| Machine / Cell | Traub Machine |
| Machine / Cell No. | SE/SSAL/06 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | NG storage open | Wrong storage method for NG part, no lock and key | X |
| Man | Unskilled Manpower | Skill matrix as per requirement | O |
| Machine | Machine Variation | JH/PM as per defined frequency | O |
| Material | Wrong material grade | Third part inspection as per RM testing plan | O |
| Tool | Tool/insert/drill worn out | Tool life monitoring as per defined frequency | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Cross MPI |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
7. Root Cause Analysis (Occurance)
| Why 1 | Extension K55 Crack |
| Why 2 | RM crack at draw stage |
| Why 3 | Internal crack not detectable. |
| Why 4 | Not feasible in MPI |
| Why 5 | Need ultrasonic test at round bar stage not done. |
| Root Cause (Occurance) | Need ultrasonic test at round bar stage not done. |
Root Cause Analysis (Outflow)
| Why 1 | Crack Part got mix up with ok part |
| Why 2 | NG material kept openly in bin without lock and keys. |
| Why 3 | lock and key not available at MPI testing supplier (Outsource) |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | lock and key not available at MPI testing supplier (Outsource) |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Ultrasonic test is being done at round bar stage after draw process | Mr. Ganesh Chavan | 25/06/2024 | 25/06/2024 | Completed |
| Outflow | Lock and key provided for NG material at MPI testing supplier. | Mr. Shaikh L.N. | 26/06/2024 | 26/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Ultrasonic test is being don at draw stage at sub-supplier.( Vishwa Samrudhi Industries) |
| Inspection Method | Other |
| Other Inspection Method | ultrasonic test (UTI |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
Magnetic particle inspection after draw process 874_Occurance_Before.pptx |
| Occurance (After) |
Additional Ultrasonic test is being done at round bar stage after draw process 874_Occurance_After.pptx |
| Outflow (Before) |
lock and key not available at MPI testing supplier (Outsource) 874_Outflow_Before.pptx |
| Outflow (After) |
Lock and key provided for NG material at MPI testing supplier. 874_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, ProcessFlowChart, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Crack |