QFR No - 8000779380
Defect Details
| NC No. | 8000779380 |
| NC Date | 10/03/2022 |
| NC Submission Date | |
| Part No. | F1FA01333M |
| Part Name | FORK PIPE MACHINED-K86A |
| Supplier Name & Code | 101187-TUBE INVESTMENTS OF INDIA LIMI |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | DIMN.U/SIZE.-TOTAL LENGTH LESS ISSUE |
1. Problem Description
| Defect Description | front fork K86 fork pipe Specification = Total Length Specification = – 288.3±0.2mm,Observation= Total Length – 285.39 mm, total length less issue |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | 5btumtx43lb0oa45ujucrky4.xlsx |
Supplier Communication Details
| Quality Head Email ID | AmitVD@tii.murugappa.com |
| Plant Head/CEO Email ID | guptaajay@tii.murugappa.com |
| MD Email ID | mukeshahuja@tii.murugappa.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1320
|
0
|
0
|
800
|
0
|
2120
|
| Check Qty |
1320
|
0
|
0
|
800
|
0
|
2120
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Available lot at Endurance checked 100% - No rejection |
3. Process Flow
| Process Flow Description |
|---|
| Cut to length CNC Machining 1 CNC Machining 2 Drilling Final Inspection Packing & Despatch |
4. Process Details
| Process / Operation | CNC Machining |
| Outsource | Yes |
| Machine / Cell | CNC Machine |
| Machine / Cell No. | M08 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Loose burr got struck at the end | Verified with Loose burr at the edge condition & Observed Length undersize based on the burr thk | O |
| Material | RM Tube length undersize | RM tube verified & found OK | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10 |
7. Root Cause Analysis (Occurance)
| Why 1 | Total height under size up to 3mm |
| Why 2 | Part moved at front side |
| Why 3 | Improper face butting |
| Why 4 | Machining burr sticked at butting face |
| Why 5 | Air cleaning process not done properly |
| Root Cause (Occurance) | Air cleaning process not done properly |
Root Cause Analysis (Outflow)
| Why 1 | Skipped from final inspection |
| Why 2 | Sample inspection only |
| Why 3 | As defined in the Existing System |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Sample inspection only |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Air line provided in the Clamping chuck | Ohm Industry | 04/07/2022 | 24/03/2022 | Completed |
| Outflow | 100% inspection implemented at process and FI | Ohm Industry | 11/03/2022 | 11/03/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Final Inspection 100% Inspection added |
| Inspection Method | Other |
| Other Inspection Method | Dial Gauge |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Manual Air cleaning 10_Occurance_Before.xlsx |
| Occurance (After) |
Air cleaning Nozzle introduced 10_Occurance_After.xlsx |
| Outflow (Before) |
Sample inspection 10_Outflow_Before.xlsx |
| Outflow (After) |
100% Inspection at Final Inspection 10_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | K86 Model |
12. Document Review
| Documents | PFMEA, WISOP |
| Specify Other Document | Q- Alert displayed |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |