QFR No - 7001036712
Defect Details
| NC No. | 7001036712 |
| NC Date | 25/07/2024 |
| 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 | LENGTH UNDERSIZE-Short Lenght (287.43) |
1. Problem Description
| Defect Description | Specification 288.3+0.2/-0.2 observation 287.43 undersize. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 1005 |
| Is Defect Repeatative? | Yes |
| 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 |
1005
|
0
|
0
|
1000
|
500
|
2505
|
| Check Qty |
1005
|
0
|
0
|
1000
|
500
|
2505
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All available material at ETL end & In-house are re - inspected with Conventional Length 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 N0 -5 |
| Machine / Cell No. | CELL N0 -5 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Raw tube length U/s | Verified Records & found ok | O |
| Man | Tube come back due to Back Pressure | Verified through Gamba &found Tube come back due to Back Pressure. Operator has to Judge for resting | X |
| Machine | Machine Parameter | Verified through Gemba observation and found all Machine Parameter as per Control Plan | O |
| Method | Wrong Setup | Verified Setup Reports & found OK. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Pokayoke |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | sampleplan |
7. Root Cause Analysis (Occurance)
| Why 1 | Length under size found at customer end (Specification 288.3+0.2/-0.2 observation 287.63 mm ) |
| Why 2 | Excess Material cut during Tube facing operation in CNC Machining. |
| Why 3 | Tube hold away from Stopper. |
| Why 4 | Tube come back due to Back Pressure. Operator has to Judge for resting on Stopper |
| Why 5 | |
| Root Cause (Occurance) | Tube come back due to Back Pressure. Operator has to Judge for resting on Stopper |
Root Cause Analysis (Outflow)
| Why 1 | Length under size found at customer end (Specification 288.3+0.2/-0.2 observation 287.63 mm ) |
| Why 2 | skip from proxy Sensor on Drilling M/c & 100 % conventional length gauge |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | skip from 100 % conventional length gauge |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | OK & Not OK Master sample made for verification of conventional length gauge. | Abishek Yadav | 06/08/2024 | 05/08/2024 | Completed |
| Occurance | Additional Tool added on CNC m/c Tool Head for Tube resting on Stopper on Cell No - 05. | Palak Shah | 06/08/2024 | 05/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % Inspection with Conventional Length Gauge for Next 1 Month. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Tube come back due to Back Pressure. Operator has to Judge for resting on Stopper. No Provision to ensure 965_Occurance_Before.pptx |
| Occurance (After) |
Additional Tool added on CNC m/c Tool Head for Tube resting on Stopper 965_Occurance_After.pptx |
| Outflow (Before) |
No Master samples of OK & NOT OK tube for Verification at Final Inspection 965_Outflow_Before.pptx |
| Outflow (After) |
Master samples of OK & NOT OK tube made for Verification at Final Inspection 965_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | all Simians control Machines. |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Specification 288.3+0.2/-0.2 observation 287.43 undersize |