QFR No - 8000785226
Defect Details
| NC No. | 8000785226 |
| NC Date | 25/04/2022 |
| NC Submission Date | |
| Part No. | F2FA15933M |
| Part Name | FORK PIPE MACHINED (K19 DRUM FF) |
| Supplier Name & Code | 100634-TATA STEEL LIMITED |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | CHAMFER NOT DONE-WRONG CHAMFER IDENTIFICATION -207 NOS. |
1. Problem Description
| Defect Description | Ring mark/step over identification marking on K-19 fork pipe |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 207 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | bipldholpur@gmail.com |
| Plant Head/CEO Email ID | anubhav.pandey@tatasteel.com |
| MD Email ID | Praveens@tatasteel.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
500
|
500
|
0
|
0
|
0
|
1000
|
| Check Qty |
500
|
500
|
0
|
0
|
0
|
1000
|
| NG Qty |
207
|
60
|
0
|
0
|
0
|
267
|
| Scrap | 267 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Supply the next lot only after 100% inspection |
3. Process Flow
| Process Flow Description |
|---|
| CNC 1st setup (Threading) - 13x1.5° Chamfer Opertaion |
4. Process Details
| Process / Operation | CNC Turning |
| Outsource | No |
| Machine / Cell | Macpower |
| Machine / Cell No. | 3 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Improper chamfer or angle in dimension 13x1.5° | In dimension 13x1.5°, ring mark/step up mark may generate at the end of chamfer due to lower angle | X |
| Man | Untrained Operator/Inspector | Operator/Inspector not fully aware if this is visible after Grinding operation | X |
| Material | No probable root cause related to material | Input material is as per specification | O |
| Machine | No probable root cause related to machine | Machine operating as per given program | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | Ring mark/step mark visible after grinding process |
| Why 2 | Step mark generate during chamfer operation 13x1.5° |
| Why 3 | Due to lower angle i.e. 1.5° |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Due to lower angle i.e. 1.5° |
Root Cause Analysis (Outflow)
| Why 1 | Ring mark/step mark visible after grinding process |
| Why 2 | Not detected during in-house inspection |
| Why 3 | Not aware if this is visible after grinding process |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Not aware if this is visible after grinding process |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 100 % Visual inspection for Ring/step mark | Pankaj | 29/05/2022 | 29/04/2022 | Completed |
| Occurance | After sample submission and further approval from ETL QA, dimension 13x1.5° changed to 13x1°55’ | Pankaj | 29/04/2022 | 29/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Dimension 13x1.5° 74_Occurance_Before.pdf |
| Occurance (After) |
Dimension 13x1°55` 74_Occurance_After.png |
| Outflow (Before) |
Inspection not done for Ring/Step mark 74_Outflow_Before.jpg |
| Outflow (After) |
100 % Visual inspection for Ring/Step mark 74_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | K19 and K1 UG |
12. Document Review
| Documents | Drawing |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | OK |