QFR No - 8000784463
Defect Details
| NC No. | 8000784463 |
| NC Date | 20/04/2022 |
| NC Submission Date | |
| Part No. | 53BHT00807 |
| Part Name | OUTER SPRING POWDER COATED-VAVE |
| Supplier Name & Code | 101048-STUMPP SCHUELE AND SOMAPPA SPR |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | PARALITY NOT OK.-BEND FOUND AT CUSTOMER END. |
1. Problem Description
| Defect Description | Parallism More, Squarness More, Bend in Spring by Checking at Surface plate |
| Detection Stage | Customer End |
| Problem Severity | Function |
| NG Quantity | 2 |
| 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 |
1500
|
0
|
0
|
0
|
0
|
1500
|
| Check Qty |
1500
|
0
|
0
|
0
|
0
|
1500
|
| NG Qty |
653
|
0
|
0
|
0
|
0
|
653
|
| Scrap | 572 |
| Rework | 81 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All the parts at Customer end inspected height gauge set up. 1500 parts checked and found 653 parts NG. No material was there in stock except at customer end. |
3. Process Flow
| Process Flow Description |
|---|
| Receipt & inspection - Visual - Storage of material - Winding RH - Stress Relieving - Grinding - Shot peening - Scragging - Lo,OD,e1 & bend sorting and correction - Powder coating - Final Inspection - Packing |
4. Process Details
| Process / Operation | Grinding and inspection |
| Outsource | No |
| Machine / Cell | Grinding / Halol |
| Machine / Cell No. | Grinding |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled Operator | Skilled operator deputed at coiling stage | O |
| Tool | Wrong magazine plate / Bush size at Grinding stage | Verified and found the magazine plate bush size correct | O |
| Machine | Grinding Surface Damage during grinding operation | Grinding surface got damaged due to not changing the grinding wheel before life completion | X |
| Method | Wrong orientation of spring in Grinding bush. | Verified and found the spring orientation as defined 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 |
| Machine | Wrong end coil winding gap during coiling | Verified and found the correct winding gap at coiling stage | O |
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 specification produced at grinding stage. |
| Why 2 | Grinding surface damage during grinding operation |
| Why 3 | Grinding wheel damage |
| Why 4 | Grinding wheel not replaced before life completion of Grinding wheel. |
| Why 5 | Limit switch height to maintain grinding wheel thickness was not set at correct position |
| Root Cause (Occurance) | Limit switch height to maintain grinding wheel thickness was not set at correct position |
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 | Limit Switch height to maintain grinding wheel thickness increased by 3mm so that grinding wheel can be disposed with minimum thickness of 15mm left. (To avoid overuse of grinding wheel, since the grinding wheel base is fit by 10mm bolts with the meatal gaurds & overuse of grinding wheel will cause spring getting struck with the bolts.) Validation performed and the limit switch height increased by 4mm found sufficient to maintain the correct grinding wheel thickness to avoid overuse of grinding wheel. | Mr. Dixit | 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 | 28/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 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) |
Grinding wheel height maintaining before the life completion was not getting monitored. Check point was not the part of Control plan. 59_Occurance_Before.pdf |
| Occurance (After) |
Limit Switch height to maintain grinding wheel thickness increased by 3mm so that grinding wheel can be disposed with minimum thickness of 15mm left. (To avoid overuse of grinding wheel, since the grinding wheel base is fit by 10mm bolts with the meatal guard & overuse of grinding wheel will cause spring getting struck with the bolts.) Control plan updated for the same. 59_Occurance_After.pdf |
| Outflow (Before) |
base plate of the right angle block small in size, where some portion of the spring base was resting outside of the base plate. 59_Outflow_Before.jfif |
| Outflow (After) |
New Right angle block with bigger Base plate introduced at inspection stage to avoid the inspection error. 59_Outflow_After.jfif |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Horizontally deployed for K0PG. |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, AuditCheckSheet |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | Accepted |