QFR No - 8000778361
Defect Details
| NC No. | 8000778361 |
| NC Date | 03/03/2022 |
| NC Submission Date | |
| Part No. | 520MD19002 |
| Part Name | COMPRESSION SPRING ( 4 PLATE VAVE) |
| Supplier Name & Code | 207123-NHK AUTOMOTIVE COMPONENTS |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | DIAMETER OVER SIZE-WIRE DIA 2.40 O/S UPTO 2.60MM |
1. Problem Description
| Defect Description | Wire diameter observed 2.6 mm as against 2.4 mm |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 2 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | aamerkhan@nhkspring.co.in |
| Plant Head/CEO Email ID | vrdhage@nhkspring.co.in |
| MD Email ID | j.mizutani@nhkspringindia.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
10000
|
0
|
0
|
15000
|
0
|
25000
|
| Check Qty |
10000
|
0
|
0
|
15000
|
0
|
25000
|
| NG Qty |
2
|
0
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Mix up sorting done . |
3. Process Flow
| Process Flow Description |
|---|
| Coiling-Stress relieving-grinding-hoscoat -preinspection-painting oiling-100% Visual sorting-Packing |
4. Process Details
| Process / Operation | Painting machine |
| Outsource | No |
| Machine / Cell | NA |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Chances of mix up at coiling | Verified at coiling process, lot taken separately, no chance of mix up spring. fallen spring scrap | X |
| Method | Chances of Mix-up at Stress relieving process | Verified at stress relieving process, lot taken separately, no chance of mix up spring. fallen spr | X |
| Method | Chances of Mix-up at Shot peening process. | verified at Shot peening process, there is no possibility of mix-up spring as one batch taken separa | X |
| Method | 1.Spring mix up painting process | 1.Painting process verify as spring remain at corner of painting tray | O |
| Man | Chances of Mix-up at Grinding process | verified at Grinding process, lot taken separately as per batch, No chance of mix up spring at Grind | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual checking |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Mix up spring found |
| Why 2 | spring mix up at painting process |
| Why 3 | Remain spring of previous lot at corner of painting tray got mix up in next lot. |
| Why 4 | Remain spring not verified after completion of lot |
| Why 5 | Remain spring checking requirement not identified in painting process |
| Root Cause (Occurance) | Remain spring checking requirement not identified in painting process |
Root Cause Analysis (Outflow)
| Why 1 | Mix up spring found |
| Why 2 | spring not detected in visual sorting |
| Why 3 | Both Ok & NG spring are similar looking |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Since ,spring not arrested in visual sorting as both spring are similar looking. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1.Now remain spring check requirement added in painting process.2)Remain spring check map made & displayed & to be monitored by remain spring check sheet after completion of every lot | S F NEHRI | 03/10/2022 | Pending | |
| Outflow | 1.100% Gauge sorting started to arrest mix up spring as there is difference between in ID of OK & NG part.(NG Part ID Is 13.50mm & OK part ID is 14.80mm) | S F NEHRI | 03/10/2022 | Pending |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Gauge sorting started at detection side to arrest mix up spring |
| 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) |
Remain check map not available at painting process 2_Occurance_Before.pdf |
| Occurance (After) |
Remain check map displayed at painting process & remain spring check sheet provided 2_Occurance_After.pdf |
| Outflow (Before) |
Only visual sorting done 2_Outflow_Before.jpg |
| Outflow (After) |
Gauge sorting started to arrest mix up spring 2_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Horizontal deployment done at painting process for all ETL Parts. |
12. Document Review
| Documents | WISOP |
| Specify Other Document | No other document |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | What is your inspection method of 100% inspection not defined and how this going to detect the problem not confirm. Also cause side action not full proof. |