QFR No - 7001052680
Defect Details
| NC No. | 7001052680 |
| NC Date | 11/09/2024 |
| NC Submission Date | |
| Part No. | S1AB00612B |
| Part Name | ADJUSTER PLATED |
| Supplier Name & Code | 100782-NICE STEEL INDUSTRIES |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | DIAMETER OVER SIZE-ID Oversize |
1. Problem Description
| Defect Description | ID oversize observed 31.70 mm against specification 30.50~30.70 mm |
| Detection Stage | Receipt |
| Problem Severity | Safety |
| NG Quantity | 8000 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | ppc.nice@batragroup.biz |
| Plant Head/CEO Email ID | ho.nice@batragroup.biz |
| MD Email ID | hitesh@batragroup.biz |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
8000
|
2000
|
0
|
2000
|
2000
|
14000
|
| Check Qty |
8000
|
2000
|
0
|
2000
|
2000
|
14000
|
| NG Qty |
2034
|
122
|
0
|
96
|
98
|
2350
|
| Scrap | 0 |
| Rework | 2034 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1-Go and No Go gauge to be made 2- Part to be checked by DVC during setup and in-process for the ID |
3. Process Flow
| Process Flow Description |
|---|
| 10 RECEIVING INSPECTION 20 STORAGE 30 BLANKING 40 1st BENDING ( `U` BENDING) 50 FINAL BENDING ( ROUNDING ) 60 MIG WELDING 70 FLAIRING 1st 80 FLAIRING 2nd 90 ID SIZING 100 SIDE GRINDING & BUFFING 110 REROUNDING 120 BROACHING 130 HEAD GRINDING 140 OUTSIDE MOVEMENT FOR PLATING 150 STORAGE & RQC INSP. OF PLATED MATERIAL 160 FINAL INSPECTION 170 PACKING & DISPATCH |
4. Process Details
| Process / Operation | Re-rounding |
| Outsource | No |
| Machine / Cell | PP |
| Machine / Cell No. | 10 to 30 Ton |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Untrained operator | Operator is skilled but not regular on this part | O |
| Man | Unskilled operator | Skill matrix available | X |
| Machine | Machine capacity was lower side used | Machine checked and found ok | X |
| Method | Part was not properly rest in mandrel | mandrel length was same as part length | O |
| Tool | Mandrel size | Mandrel check and found length was same as part length | O |
| Material | wrong material used | Material checked and found ok | X |
| Machine | Machine capacity was higher side used | Machine checked and found ok | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | Visual |
7. Root Cause Analysis (Occurance)
| Why 1 | Dia over size observed at customer end |
| Why 2 | Id not maintained at leg area due to Part leg was not properly |
| Why 3 | 3 mm part leg area was in the air due to part not properly rest at re-round mandrel |
| Why 4 | Mandrel length and part resting length was same |
| Why 5 | Mandrel length was defined as per past experience according to other similar process/part |
| Root Cause (Occurance) | 1- 3 mm part leg area was in the air due to part not properly rest at re-round mandrel 2-Madral length and part resting length was same |
Root Cause Analysis (Outflow)
| Why 1 | Defective part not found ok PDI area |
| Why 2 | Inspection was doing with plug gauge |
| Why 3 | Plug gauge was defined for inspection |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspection was doing with plug gauge |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Mandrel length increased 33±3 mm from 24.0±2 | Nimit | 10/09/2024 | 10/09/2024 | Completed |
| Occurance | Re-rounding to be started at 2 location on part by 2 stroke | Nimit | 15/09/2024 | 12/09/2024 | Completed |
| Outflow | OPL displayed | Prahlad | 10/09/2024 | 09/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Part to be checked by DVC during setup and in-process for the ID |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | Revers |
10. Evidance of Countermeasure
| Occurance (Before) |
NA 1085_Occurance_Before.png |
| Occurance (After) |
SHEET ATATCHED 1085_Occurance_After.png |
| Outflow (Before) |
NA 1085_Outflow_Before.png |
| Outflow (After) |
SHEET ATTACHED 1085_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | ID oversize observed 31.70 mm against specification 30.50~30.70 mm |