QFR No - 8000783094
Defect Details
| NC No. | 8000783094 |
| NC Date | 07/04/2022 |
| NC Submission Date | |
| Part No. | F2DZ08810B |
| Part Name | K0PG FORK BOLT |
| Supplier Name & Code | 101037-SHREE PATEL INDUSTRIES |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | DEEP MARK-MACHINING UNCLEAN |
1. Problem Description
| Defect Description | Line mark at OD 26.15 |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 35 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality_spi@rediffmail.com |
| Plant Head/CEO Email ID | planthead_spi@rediffmail.com |
| MD Email ID | rspatel_spi@rediffmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
10000
|
0
|
0
|
2618
|
0
|
12618
|
| Check Qty |
10000
|
0
|
0
|
2618
|
0
|
12618
|
| NG Qty |
1
|
0
|
0
|
2
|
0
|
3
|
| Scrap | 3 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Hold the material at all stages and inspection done accordingly . |
3. Process Flow
| Process Flow Description |
|---|
| 1. Incoming RM 2. Acid Pickling 3. Water Wash 4. Lime Wash 5. Pointing 6. Draw 7. Cutting 8. Straightening 9. Inspection 10.Packing & Dispatch 11. Incoming RM 12. Traub Turning 13. CNC 1st set up 14. CNC 2nd set up 15. Plating 16. Inspection 17. Packing & Dispatch |
4. Process Details
| Process / Operation | Draw |
| Outsource | No |
| Machine / Cell | Draw Machine |
| Machine / Cell No. | Draw Line |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Awareness of Inspector | Operator was not aware about inspection std | O |
| Machine | Die Check sheet | During process Verification no Die check point available | O |
| Method | Rod Draw | During process verification a deep line mark generated on rod during draw operation. | O |
| Machine | Die Life Monitoring | During process Verification no Die life monitoring record available | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 |
7. Root Cause Analysis (Occurance)
| Why 1 | Deep Line mark part reached at customer end. |
| Why 2 | Deep line mark part generate during CNC operation. |
| Why 3 | Deep line mark found on input rod . |
| Why 4 | At draw operation chips observed on rod, which remains a deep line on rod during draw process. |
| Why 5 | There was No checkpoint & WI available at draw operation to check the input & output material of rod. |
| Root Cause (Occurance) | At draw operation chips observed on rod which generate / remains a deep line on rod during draw operat |
Root Cause Analysis (Outflow)
| Why 1 | Deep Line mark part reached at customer end. |
| Why 2 | Inspector not detected deep line mark part during final inspection . |
| Why 3 | Inspector was not aware about the defect. |
| Why 4 | No inspection std available at final inspection station. |
| Why 5 | |
| Root Cause (Outflow) | No inspection std available at final inspection station. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1. WI made to check the Input & Output material & also FIR ,IIR made to check the draw bar after draw process . 2. Draw Die checkpoint check sheet made . 3. Die life monitoring to be started | Pradeep Tripathi | 18/02/2022 | 18/02/2022 | Completed |
| Outflow | 1. Training provided to the final inspector about the problem and inspection std. 2. 200% visual inspection started. | Pradeep Tripathi | 18/02/2022 | 18/02/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 200% Visual Inspection |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection. |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Die Check Sheet 45_Occurance_Before.zip |
| Occurance (After) |
Die Check Sheet 45_Occurance_After.zip |
| Outflow (Before) |
Inspection Std 45_Outflow_Before.xlsx |
| Outflow (After) |
Inspection Std 45_Outflow_After.zip |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | No |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 0 |
| Reason for submission | Draw Die PM Sheet updated but revision number not changed. Also Document Control plan and PFMEA not updated as per revised Checking frequency and possible causes. |