QFR No - 7001043627
Defect Details
| NC No. | 7001043627 |
| NC Date | 13/08/2024 |
| NC Submission Date | |
| Part No. | S1HT05507B |
| Part Name | OUTER SPRING - K1JF |
| Supplier Name & Code | 100186-SAGAR SPRINGS PRIVATE LIMITED |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | MIX UP OTHER MODEL-Wrong part Recieved |
1. Problem Description
| Defect Description | Mix up other model (Wrong part) |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 266 |
| 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 |
4704
|
0
|
0
|
1500
|
0
|
6204
|
| Check Qty |
4704
|
0
|
0
|
1500
|
0
|
6204
|
| NG Qty |
266
|
0
|
0
|
0
|
0
|
266
|
| Scrap | 0 |
| Rework | 0 |
| Under Deviation | 266 |
| Containment Action |
|---|
| Sagar Springs person visited ETL-Sanand and segregated. |
3. Process Flow
| Process Flow Description |
|---|
| Coiling - Tempering - Grinding - Shot Peening - Tempering - Powder Coating - Final Inspection - Packing - Dispatch |
4. Process Details
| Process / Operation | Dispatch |
| Outsource | No |
| Machine / Cell | Dispatch |
| Machine / Cell No. | Dispatch |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Untrained dispatch personnel | Dispatch personnel are experienced and skilled | O |
| Method | Similar looking springs with same packing standard stored in dispatch area | Chance of loading other model springs during loading dispatch vehicle | X |
| Method | Similar looking springs mix up in different process stages | Similar looking springs processed separately | O |
| Machine | Similar looking springs mix up at coiling machine | After completing one order parts moved to tempering and next order taken on coiling machine | O |
| Man | Untraining packing personnel | Packing personnel are experienced and skilled | O |
| Man | Untrained inspector | Inspector is experienced and skilled | O |
| Material | Wrong material taken for process | Through out process similar looking parts handled separately | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Similar looking springs with same packing standard stored in dispatch area |
| Why 2 | Similar looking springs with same packing standard stored side by side |
| Why 3 | During loading dispatch vehicle other model springs bins loaded |
| Why 4 | Similar looking parts and same packing standard |
| Why 5 | |
| Root Cause (Occurance) | Similar looking parts and same packing standard |
Root Cause Analysis (Outflow)
| Why 1 | Mix up not detected at Inspection |
| Why 2 | Mix up occurred at dispatch - after inspection |
| Why 3 | During loading dispatch vehicle other model springs bins loaded |
| Why 4 | Similar looking parts and same packing standard |
| Why 5 | |
| Root Cause (Outflow) | Similar looking parts and same packing standard |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Similar looking parts will be stored in separate area to prevent mix up during dispatch vehicle loading | Dispatch | 20/08/2024 | 20/08/2024 | Completed |
| Occurance | Similar looking springs one model springs packed in carton box and shifted to bins during dispatch vehicle loading | Dispatch | 20/08/2024 | 20/08/2024 | Completed |
| Outflow | Before dispatch visually verified, part model confirmed and loaded in vehicle | Dispatch | 20/08/2024 | 20/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Visual verification before loading into dispatch vehicle |
| Inspection Method | Other |
| Other Inspection Method | Visual verification |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Similar looking parts with same packing standard stored side by side in dispatch area 1022_Occurance_Before.ppt |
| Occurance (After) |
Similar looking parts will be stored in separate area to prevent mix up during dispatch vehicle loading
Similar looking springs one model springs packed in carton box and shifted to bins during dispatch vehicle loading 1022_Occurance_After.ppt |
| Outflow (Before) |
After packing no verification 1022_Outflow_Before.ppt |
| Outflow (After) |
Before dispatch visually verified, part model confirmed and loaded in vehicle 1022_Outflow_After.ppt |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applicable for similar looking springs |
12. Document Review
| Documents | PFMEA |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Mix up other model of similar type. |