QFR No - 8000782618
Defect Details
| NC No. | 8000782618 |
| NC Date | 03/04/2022 |
| 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 | NOT AS PER SPECIFICATION-BEND FOUND AT CUSTOMER END DUE TO PARLL. |
1. Problem Description
| Defect Description | Bend Found at Customer End due to Parallelism, Squarness NG i.e. Parallelism :- 1.66, 2.04, 2.41 Squarnes :- 7.5, 6.8, 8.0 it is repeatative at M/s ETLS end. |
| Detection Stage | Customer End |
| Problem Severity | Function |
| NG Quantity | 3 |
| 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 |
3080
|
0
|
0
|
0
|
700
|
3780
|
| Check Qty |
3080
|
0
|
0
|
0
|
700
|
3780
|
| NG Qty |
71
|
0
|
0
|
0
|
6
|
77
|
| Scrap | 77 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All the parts at Customer end inspected height gauge set up. 3080 parts checked and found 71 parts NG. Available internal parts segregated with Right angle and dial gauge set up. Available Qty of 700 nos. checked, 6 part found having ID undersize. |
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 Operation |
| Outsource | No |
| Machine / Cell | SGM-3 / Halol |
| Machine / Cell No. | Grinding Cell |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Wrong end coil winding gap during coiling | Verified and found the correct winding gap at coiling stage | O |
| Man | Unskilled Operator | Skilled operator deputed at each stage | O |
| Tool | Wrong magazine plate / Bush size at Grinding stage | Verified and found the magazine plate bush oversize by 1mm. | X |
| Method | Wrong orientation of spring in Grinding bush. | Verified and found the spring orientation as defiened in work instruction (Bigger side upward) | O |
| Method | Inspection method error | Verified & found the base plate of the right angle block small in size, where some portion of the sp | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Sp. 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 | Parts with parallelism more than 1mm produced at grinding stage. |
| Why 2 | Grinding plate bush size observed 1mm more than specified. (Bush I.D observed 56.7mm against 55.7 mm max. |
| Why 3 | Inspection frequency for Bush size I.D monitoring found less |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Inspection frequency for Bush size I.D monitoring found less |
Root Cause Analysis (Outflow)
| Why 1 | Parallelism out of specification part escaped from inspection |
| Why 2 | Dial gauge reading observed less with compare to readings at height gauge |
| Why 3 | Verified & found the base plate of the right angle block small in size, where some portion of the spring base was resting outside of the base plate. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Verified & found the base plate of the right angle block small in size, where some portion of the spring base was resting outside of the base plate. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | New grinding plate with new Bushes with correct I.D produced and installed at Grinding stage. | Mr. Dixit | 28/04/2022 | 28/04/2022 | Completed |
| Occurance | Inspection frequency increased from 1 month to every set up of grinding. Control for Bush I.D monitoring added in Control plan. | Mr. Maulesh | 28/04/2022 | 28/04/2022 | Completed |
| Outflow | New Right angle block with bigger Base plate introduced at inspection stage to avoid the inspection error. | Mr. Maulesh | 21/04/2022 | 21/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection frequency increased from 1 month to every set up of grinding. Control for Bush I.D monitoring added in Control plan New Right angle block with bigger Base plate introduced at inspection stage to avoid the inspection error. |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Inspection frequency for Bush size I.D monitoring found less. Grinding Bush I.D observed oversize 42_Occurance_Before.pdf |
| Occurance (After) |
Inspection frequency increased from 1 month to every set up of grinding. Control for Bush I.D monitoring added in Control plan. New Grinding plate with correct bush I.D produced and installed. 42_Occurance_After.pdf |
| Outflow (Before) |
Right angle block base was short, where some portion of the spring base falling out (of the base plate) during inspection. 42_Outflow_Before.jfif |
| Outflow (After) |
New Right angle block with bigger Base plate introduced at inspection stage to avoid the inspection error. 42_Outflow_After.jfif |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applicable for all the OC springs. |
12. Document Review
| Documents | ControlPlan, PMCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | Accepted |