QFR No - 7001049474
Defect Details
| NC No. | 7001049474 |
| NC Date | 02/09/2024 |
| NC Submission Date | |
| Part No. | 520HP00212 |
| Part Name | OIL SEAL STOPPER1 |
| Supplier Name & Code | 100179-BELLITE SPRINGS PVT.LTD. |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | DIMN.U/SIZE.-Dim 13.5 undersize |
1. Problem Description
| Defect Description | Dim 13.5 mm found undersize i.e. 12.644 mm |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 30000 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qc.plant2@bellitespring.com |
| Plant Head/CEO Email ID | dayanandkore@bellitesprings.com |
| MD Email ID | harsjeet.bhatt@bellitesprings.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
53900
|
0
|
0
|
20000
|
0
|
73900
|
| Check Qty |
53900
|
0
|
0
|
20000
|
0
|
73900
|
| NG Qty |
30000
|
0
|
0
|
0
|
0
|
30000
|
| Scrap | 0 |
| Rework | 30000 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Re verify the Existing lot for the issue |
3. Process Flow
| Process Flow Description |
|---|
| RM Inward-Coiling-Stress Relieving-Checking-Packing-Dispatch |
4. Process Details
| Process / Operation | Coiling |
| Outsource | No |
| Machine / Cell | CNC Coiling |
| Machine / Cell No. | CNC-02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Incomplete stroke of notching tool. | Checked & found not ok | 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 | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Circlip Gap U/S |
| Why 2 | The notch stroke was not completed. |
| Why 3 | the stroke stopper was loose |
| Why 4 | the bolt was loosened |
| Why 5 | the check nut was missing. |
| Root Cause (Occurance) | the check nut was missing. |
Root Cause Analysis (Outflow)
| Why 1 | Circlip Gap U/S |
| Why 2 | To address the issue of undersized circlips not being identified during the final inspection stage |
| Why 3 | due to sampling-based checks with the digital vernier caliper. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | due to sampling-based checks with the digital vernier caliper. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | New Check Nut is use and stopper is tightened. | Mr. Sujit M. | 19/08/2024 | 19/08/2024 | Completed |
| Outflow | We have started 100% inspection at the final inspection stage | Mr. Sujit | 07/09/2024 | 07/09/2024 | Completed |
| Occurance | the `Nut and Bolt` checkpoint has been added to the process setup approval report.. | Mr. Sujit M. | 20/08/2024 | 20/08/2024 | Completed |
| Outflow | The PDI report has been updated to include the use of the gap gauge | Mr. Sujit | 07/09/2024 | 07/09/2024 | Completed |
| Occurance | Tightening by two check nuts one above the other. | Mr. Sujit M. | 10/09/2024 | 10/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | We are now using a gap gauge for checking circlips at the PDI stage |
| 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) |
Previously, only one bolt was used. 1051_Occurance_Before.jpg |
| Occurance (After) |
Now, Tightening by two check nuts one above the other. 1051_Occurance_After.jpg |
| Outflow (Before) |
Previously, we checked the circlip using a vernier caliper during the PDI stage 1051_Outflow_Before.xlsx |
| Outflow (After) |
We are now using a gap gauge for checking circlips at the PDI stage 1051_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | CNC-02 |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | Setup Approval |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Dim 13.5 mm found undersize i.e. 12.644 mm |