QFR No - 8000782060
Defect Details
| NC No. | 8000782060 |
| NC Date | 27/03/2022 |
| NC Submission Date | |
| Part No. | S2HT52107B |
| Part Name | OUTER SPRING K0PG |
| Supplier Name & Code | 101048-STUMPP SCHUELE AND SOMAPPA SPR |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | DIMETER UNDERSIZE-INNERDIA UNDERSIZE |
1. Problem Description
| Defect Description | ID Under Size |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | pathan.ak@ssssprings.com |
| Plant Head/CEO Email ID | udham.singh@ssssprings.com |
| MD Email ID | rln@ssssprings.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2016
|
0
|
0
|
0
|
1200
|
3216
|
| Check Qty |
2016
|
0
|
0
|
0
|
1200
|
3216
|
| NG Qty |
1
|
0
|
0
|
0
|
1
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Available internal parts segregated 100 %. Available Qty of 1200 nos checked, 1 part found having ID undersize. All the springs will be provided with small line on small ID end for next 3 lots. |
3. Process Flow
| Process Flow Description |
|---|
| Recipt & inspection - Visual - Storage of material - Winding RH - Stress Relieving - Grinding - Shot peening - Scragging - Lo,OD,e1 & bend sorting and correction - Stress Relieving (LTA) - Powder coating - Final Inspection - Packing |
4. Process Details
| Process / Operation | Grinding |
| Outsource | No |
| Machine / Cell | SGM-2 (Grinding machine) |
| Machine / Cell No. | Grinding |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Wrong Set up during coiling | Verified and found the correct setting was done. | O |
| Man | Unskilled Operator | Skilled operator deputed at coiling stage | O |
| Tool | Wrong or damaged magazine plate at Grinding stage | Verified and found the correct magazine plate for grinding of this part | O |
| Method | Wrong orientation of spring in Grinding bush. | End moved inside due to wrong placement of spring in grinding bush | X |
| Method | Part mix up | Verified & found that NG parts mixed-up with OK parts. | 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 | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Problem occur during grinding operation. |
| Why 2 | Spring in Guide bush placed with wrong orientation (Bigger side down in place of upward) |
| Why 3 | spring orientation during grinding not specified & documented |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | spring orientation during grinding not specified & documented |
Root Cause Analysis (Outflow)
| Why 1 | Problem occur during 100% ID inspection at powder coating. |
| Why 2 | Captured ID tight parts mixed-up with Ok parts. |
| Why 3 | Both the parts were kept nearby on inspection table by operator. |
| Why 4 | No separator for the OK and NG parts at inspection table. |
| Why 5 | |
| Root Cause (Outflow) | No separator for the OK and NG parts at inspection table. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Work instruction revised to add the spring orientation (Bigger side up) in Grinding bush during grinding operation & training provided to the operators accordingly. | Mr. Dixit | 07/04/2022 | 07/04/2022 | Completed |
| Occurance | ID inspection and Control added at Grinding Stage, Control plan revised for the same. | Mr. Maulesh | 06/04/2022 | 06/04/2022 | Completed |
| Outflow | Separator provided on inspection table with proper identification to avoid mix-up | Mr. Shashank | 06/04/2022 | 06/04/2022 | Completed |
| Outflow | Awareness training given to the operators to keep NG parts in red bin. | Mr. Shashank | 07/04/2022 | 06/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Sampling inspection for ID started at Grinding stage, control plan revised for the same. |
| 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) |
No ID inspection at Grinding stage,
Spring orientation in Grinding was not specified in Work instruction 26_Occurance_Before.pdf |
| Occurance (After) |
ID inspection started at Grinding stage, Control plan revised for the same.
Work instruction revised to add the spring orientation (Bigger side up) in Grinding bush during grinding operation & training provided to the operators accordingly. 26_Occurance_After.jpg |
| Outflow (Before) |
OK and reworkable parts were kept at the same inspection table without any separator. 26_Outflow_Before.png |
| Outflow (After) |
Separator provided on inspection table to place OK and reworkable parts separate to avoid mix-up of OK and NG parts 26_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Inspection for ID started for all the OC springs. |
12. Document Review
| Documents | ControlPlan, WISOP |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | Accepted |