QFR No - 8000782049
Defect Details
| NC No. | 8000782049 |
| NC Date | 27/03/2022 |
| NC Submission Date | |
| Part No. | F1GN01102B |
| Part Name | MAIN SPRING K86A |
| Supplier Name & Code | 101225-HELICAL SPRINGS |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | HIGHT U/SIZE.-TOTAL HIGHT UNDERSIZE |
1. Problem Description
| Defect Description | Total Length Under Size and Over Size i.e. 244.42, 213.11 mm |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 231 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | arun@helicalsprings.in |
| Plant Head/CEO Email ID | shaikhmoin@helicalsprings.in |
| MD Email ID | ataneja@helicalsprings.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
12000
|
16000
|
0
|
5800
|
6000
|
39800
|
| Check Qty |
10000
|
16000
|
0
|
5800
|
6000
|
37800
|
| NG Qty |
231
|
42
|
0
|
58
|
0
|
331
|
| Scrap | 273 |
| Rework | 58 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% inspection done for length at ETL & Warehouse. |
3. Process Flow
| Process Flow Description |
|---|
| Raw Material Receipt & Inspection, Coiling, Stress Relieving, End Grinding, Shot Peening, Scragging, Length & Wavyness checking, Strain-aging, Surface Finish- Oiling, Final Inspection/ PDI, Packing, Dispatch |
4. Process Details
| Process / Operation | Coiling |
| Outsource | No |
| Machine / Cell | NA |
| Machine / Cell No. | CNC Coiling |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled operator | Skill Matrix checked found ok | O |
| Method | Improper length setting | Improper locking of length gauge | X |
| Material | As per Drawing | RMTC checked found ok | O |
| Method | 1.Improper material handing | Setup part mix with ok part | X |
| Machine | Herdon | Found 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 | 29 / 10000 |
7. Root Cause Analysis (Occurance)
| Why 1 | length short |
| Why 2 | During setup length short spring coiled |
| Why 3 | Setup quantity mix with the ok material |
| Why 4 | No provision was available for setup part storage |
| Why 5 | |
| Root Cause (Occurance) | No provision was available for setup part storage |
Root Cause Analysis (Outflow)
| Why 1 | length short |
| Why 2 | Length gauge setting disturbed |
| Why 3 | Improper locking of Length gauge |
| Why 4 | No cross check method for length gauge verification |
| Why 5 | |
| Root Cause (Outflow) | No cross check method for length gauge verification |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 1.Free length tolerance band reduced from +4.0 mm to +3.50 mm 2.Dedicated length gauge will be introduced for K0LA main spring (fixed type) 3.Control plan changed and updated | Arun Kumar | 30/03/2022 | 28/03/2022 | Completed |
| Occurance | 1.Yellow bin introduced at coiling to keep suspected/setup part 2.OPL displayed at coiling 3.Training provided to the operator and recorded the same | Arun Kumar | 30/03/2022 | 24/03/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Free length tolerance band reduced from +4.0 mm to +3.50 mm |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 29 / 10000 |
10. Evidance of Countermeasure
| Occurance (Before) |
Yellow bin not Available 25_Occurance_Before.pdf |
| Occurance (After) |
Yellow bin introduced at coiling to keep suspected/setup part 25_Occurance_After.pdf |
| Outflow (Before) |
Free length gauge tolerance 4.00 mm 25_Outflow_Before.pdf |
| Outflow (After) |
Free length tolerance band reduced from +4.0 mm to +3.50 mm 25_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Similar Part. |
12. Document Review
| Documents | |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Verified and found effective till date |