QFR No - 8000782917
Defect Details
| NC No. | 8000782917 |
| NC Date | 06/04/2022 |
| 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 O/SIZE.-TOTAL HIGHT OVERSIZE |
1. Problem Description
| Defect Description | Total Length Over Size |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 7 |
| 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 |
10000
|
0
|
0
|
0
|
8950
|
18950
|
| Check Qty |
10000
|
0
|
0
|
0
|
8950
|
18950
|
| NG Qty |
7
|
0
|
0
|
0
|
0
|
7
|
| Scrap | 7 |
| Rework | 0 |
| 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. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Improper material handing | Setup part mix with ok part | X |
| Material | As per Drawing | RMTC checked found ok | O |
| Machine | Herdon | Found ok | O |
| Man | Unskilled operator | Skill Matrix checked 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 | 5 Nos |
7. Root Cause Analysis (Occurance)
| Why 1 | length over size |
| 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) | Yellow bin introduced at coiling to keep suspected/setup part |
Root Cause Analysis (Outflow)
| Why 1 | length over size |
| 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) | Dedicated length gauge will be introduced for K0LA main spring (fixed type) |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Dedicated length gauge will be introduced for K0LA main spring (fixed type) | Mr. Arun Kumar | 30/04/2022 | 28/04/2022 | 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 | Mr. Nilesh Kapure | 14/04/2022 | 12/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | Free length will be introduced for K0LA main spring (fixed type) |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 30/Lot |
10. Evidance of Countermeasure
| Occurance (Before) |
No 100% marking on springs. 44_Occurance_Before.pdf |
| Occurance (After) |
100% marking on spring After free length checking. 44_Occurance_After.pdf |
| Outflow (Before) |
Red bin & Yellow bin not cover properly. 44_Outflow_Before.pdf |
| Outflow (After) |
Red bin & Yellow bin cover properly 44_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 | 12000 |
| Reason for submission | Found Ok |