QFR No - 7001062399
Defect Details
| NC No. | 7001062399 |
| NC Date | 11/10/2024 |
| NC Submission Date | |
| Part No. | S1JL03533B |
| Part Name | PISTON ROD BOTH SIDE MACHINED |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | LENGTH UNDERSIZE-T.LENGTH U/S SPE=173.30+/-0.20 OBS=172.1 |
1. Problem Description
| Defect Description | LENGTH UNDERSIZE-T.LENGTH U/S SPE=173.30+/-0.20 OBS=172.1 |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 14 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@mahavirind.co.in |
| Plant Head/CEO Email ID | planthead@mahavirind.co.in |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
600
|
0
|
0
|
0
|
0
|
600
|
| Check Qty |
600
|
0
|
0
|
0
|
0
|
600
|
| NG Qty |
14
|
0
|
0
|
0
|
0
|
14
|
| Scrap | 14 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Material segregation at Customer End |
3. Process Flow
| Process Flow Description |
|---|
| RM inward - store - Band Saw Parting -Straightening - CNC-1( Mounting Side - CNC-2( Piston Side)- Final inspection - Packing - Dispatch - Transport |
4. Process Details
| Process / Operation | CNC-2( Piston Side |
| Outsource | Yes |
| Machine / Cell | CNC-9 |
| Machine / Cell No. | CNC Section |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Machining Process & Inspection Method Wrong | Machining Process is ok But Inspection Method Wrong | X |
| Man | Unskilled operator | As per Skilled Matrix Operator is skilled | O |
| Tool | Wrong Tool Insert Use | Correct carbide Insert Facing and Turning Tool Use | O |
| Material | Wrong Grade And other grade Material Use | Correct Grade F15.4-EN8D Material use . | O |
| Method | Machine Condition Not OK | As per Daily Check sheet Machine Condition was ok but Stopper Not OK | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 20Nos /Bin |
7. Root Cause Analysis (Occurance)
| Why 1 | LENGTH UNDERSIZE-T.LENGTH U/S SPE=173.30+/-0.20 OBS=172.1 |
| Why 2 | During piston side machining, the part was resting too deep in the CNC chuck |
| Why 3 | CNC Resting stopper lock Nut Loose |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | CNC Resting stopper lock Nut Loose. |
Root Cause Analysis (Outflow)
| Why 1 | LENGTH UNDERSIZE-T.LENGTH U/S SPE=173.30+/-0.20 OBS=172.1 |
| Why 2 | Sampling measuring Frequency Very Low. |
| Why 3 | Hourly 5 Nos Inspection By Inspector. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Sampling measuring Frequency Very Low. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Arrange an additional lock nut to secure the resting stopper lock nut. | Production Head | 14/10/2024 | 14/10/2024 | Completed |
| Outflow | The length measurement sampling frequency has been increased to 10 samples instead of 5. | Quality Head | 14/10/2024 | 14/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Length measurement sampling frequency has been increased to 10nos samples instead of 5.nos |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10Nos |
10. Evidance of Countermeasure
| Occurance (Before) |
CNC Resting stopper lock Nut Loose. 1140_Occurance_Before.jpg |
| Occurance (After) |
Arrange an additional lock nut to secure the resting stopper lock nut. 1140_Occurance_After.jpg |
| Outflow (Before) |
Sampling measuring Frequency Very Low. 1140_Outflow_Before.docx |
| Outflow (After) |
The length measurement sampling frequency has been increased to 10Nos samples instead of 5Nos. 1140_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Piston Rods |
12. Document Review
| Documents | ControlPlan, PFMEA, JHCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |