QFR No - 8000783853
Defect Details
| NC No. | 8000783853 |
| NC Date | 14/04/2022 |
| NC Submission Date | |
| Part No. | 550BZ04302 |
| Part Name | CAP OIL LOCK - DT |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-PARALLELISM NOT OK |
1. Problem Description
| Defect Description | End Face Parallelism Not Ok |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 144 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@apw3.co.in |
| Plant Head/CEO Email ID | kurund.ma@sharp-engineers.com |
| MD Email ID | urkhandelwal@sharp-engineers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
900
|
0
|
0
|
0
|
0
|
900
|
| Check Qty |
900
|
0
|
0
|
0
|
0
|
900
|
| NG Qty |
68
|
0
|
0
|
0
|
0
|
68
|
| Scrap | 0 |
| Rework | 68 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Under cut added in three chuck jaw for burr removing . |
3. Process Flow
| Process Flow Description |
|---|
| CNC stage |
4. Process Details
| Process / Operation | CNC Machining |
| Outsource | No |
| Machine / Cell | Machine Chop |
| Machine / Cell No. | SE/CNCE/04 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled operator | Skill matrix monitoring | O |
| Tool | Insert Worn out | Tool life monitoring | O |
| Material | Wrong material | MTC & Third party report | O |
| Machine | Three chuck jaw under cut | Missing | X |
| Method | Improper loading | Observed | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10:100 |
7. Root Cause Analysis (Occurance)
| Why 1 | 0.02mm PARALLELISM NOT OK |
| Why 2 | Improper part loading |
| Why 3 | Less under cut in chuck jaw |
| Why 4 | Under cut removed while jaw boring |
| Why 5 | |
| Root Cause (Occurance) | Under cut removed while jaw boring |
Root Cause Analysis (Outflow)
| Why 1 | Excess parallelism |
| Why 2 | Sampling basis inspection as per IS:2500 |
| Why 3 | Following checking frequency as per defined control plan |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Following checking frequency as per defined control plan (32:1200 Nos.) |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 100% inspection started before dispatch | Mr. Shaikh L.N. | 20/04/2022 | 20/04/2022 | Completed |
| Occurance | 2mm under cut added in chuck jaw | Mr. Pandhre Datta | 20/04/2022 | 20/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Checking frequency defined 100:1000 |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 100:1000 |
10. Evidance of Countermeasure
| Occurance (Before) |
Burr cleaning done thru air pressure , improper cleaning because there is no under cut in clamping chuck jaw, burr, chip not removed from Chuck jaw properly. 50_Occurance_Before.pptx |
| Occurance (After) |
Cleaning started thru air gun by providing high air pressure (4 Bar), burr chip removed from chuck jaw properly and defect eliminated because under cut added up to 1.5mm. 50_Occurance_After.pptx |
| Outflow (Before) |
Sampling basis inspection as per IS:2500 (Sample size 32:1200 as per IS:2500) 50_Outflow_Before.jpg |
| Outflow (After) |
Sample size increased from 32:1200 to 100:1200 Nos. 50_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | CAP OIL LOCK J1D |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | - |
13. Effectiveness Of Action
| Reviewed Quantity | 300 |
| Reason for submission | Next 2 lot inspected and no defect found |