QFR No - 7001034092
Defect Details
| NC No. | 7001034092 |
| NC Date | 16/07/2024 |
| NC Submission Date | |
| Part No. | F2FA19033M |
| Part Name | K0PG FORK PIPE MACHINED |
| Supplier Name & Code | 101109-TUBE INVESTMENTS OF INDIA LIMI |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | DIMETER UNDERSIZE-OD Groove Dia undersize |
1. Problem Description
| Defect Description | Groove OD undersize 28.2-0.2 observed 27.85 mm |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 53 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | anandms@tii.murugappa.com |
| Plant Head/CEO Email ID | girisha@tii.murugappa.com |
| MD Email ID | mukeshahuja@tii.murugappa.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1500
|
0
|
0
|
500
|
500
|
2500
|
| Check Qty |
1500
|
0
|
0
|
500
|
500
|
2500
|
| NG Qty |
53
|
0
|
0
|
0
|
0
|
53
|
| Scrap | 53 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All available material at ETL end & In-house are re - inspected with Snap Gauge. |
3. Process Flow
| Process Flow Description |
|---|
| INWARD - CNC MACHINING - DRILLING - DIBURRING - FINAL INSPECTION - PACKING - DISPATCH TO ETL. |
4. Process Details
| Process / Operation | CNC Machining |
| Outsource | No |
| Machine / Cell | Cell No -3 |
| Machine / Cell No. | Cell No -3 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Inspection Frequency | Verified records and observed that component inspected at the time of setup & every Hour | O |
| Tool | Insert Broken | discussion with operator there was insert broken incidence. Operator has not checked parts produced | X |
| Method | Machining Parameter | Verified through Gemba observation and found all Machine Parameter as per Control Plan | O |
| Material | Raw tube OD U/s | Verified & found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 nos Hour |
7. Root Cause Analysis (Occurance)
| Why 1 | Groove OD Dim. 28.2-0.2 mm found under size observed 27.85 mm at Customer end. |
| Why 2 | Groove OD Dim. 28.2-0.2 mm under size during CNC Machining process due to CNC Insert Point broken before changing frequency. |
| Why 3 | due to burr/ chips interrupted bet Insert point & material |
| Why 4 | Insufficient coolant flow on insert point. |
| Why 5 | Coolant pipe partially chock -up. |
| Root Cause (Occurance) | Coolant pipe partially chock -up. |
Root Cause Analysis (Outflow)
| Why 1 | Groove OD Dim. 28.2-0.2 mm found under size observed 27.85 mm at Customer end. |
| Why 2 | Escape from Inspection |
| Why 3 | No inspection at Final Inspection for groove OD Size. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No inspection at Final Inspection for groove OD Size. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | inspection point added at Final Inspection for groove OD Size on sampling basis with snap Gauge | Mr. Abishek Yadav | 02/08/2024 | 22/07/2024 | Completed |
| Occurance | Coolant pipe choke -up corrected. | Mr. Palak | 02/08/2024 | 22/07/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | inspection point added at Final Inspection for groove OD Size on sampling basis with snap Gauge |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | after 5 no |
10. Evidance of Countermeasure
| Occurance (Before) |
Coolant pipe Partially Choke -up. 942_Occurance_Before.pptx |
| Occurance (After) |
Coolant pipe Partially Choke -up cleared 942_Occurance_After.pptx |
| Outflow (Before) |
No Inspection at Final Inspection 942_Outflow_Before.pptx |
| Outflow (After) |
Quality alert displayed at Final Inspection for Check after every 05 Nos with snap gauge & Training provided for inspector & operator. 942_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | K-86 -A |
12. Document Review
| Documents | WISOP |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Groove OD undersize 28.2-0.2 observed 27.85 mm |