QFR No - 8000785714
Defect Details
| NC No. | 8000785714 |
| NC Date | 29/04/2022 |
| NC Submission Date | |
| Part No. | F2CK00403B |
| Part Name | CAP NUT XF1C1_1D1 |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-CAP NUT M22 THREAD NOGO PASS |
1. Problem Description
| Defect Description | M22 X 1 X 6H THREADING NOGO PASS- CC FROM M/S SUZUKI |
| Detection Stage | Customer End |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | dca2kxp4ecj4q3wvvbonetym.pptx |
Supplier Communication Details
| Quality Head Email ID | quality@sharp-engineers.com |
| 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 |
500
|
0
|
0
|
500
|
900
|
1900
|
| Check Qty |
500
|
0
|
0
|
500
|
0
|
1000
|
| NG Qty |
112
|
0
|
0
|
97
|
0
|
209
|
| Scrap | 209 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation of pipeline material including ETL end material. |
3. Process Flow
| Process Flow Description |
|---|
| 10 RM Inward Inspection 20 RM Storage 30 Parting & Drilling 40 CNC-1st Setup 50 CNC-2nd Setup 60 Plating 70 Inward Inspection 80 Final Inspection 90 PDI 100 Packing & Forwarding |
4. Process Details
| Process / Operation | CNC Machining |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | 3 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Pre-Thread Dia O/S | Observed on Higher Side upto 22.10~22.20mm | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | As per Pla |
7. Root Cause Analysis (Occurance)
| Why 1 | M22 Threading No-go Pass observed at Customer End. |
| Why 2 | Observed Pre-Thread Dia on Higher side upto 21.10~21.20mm |
| Why 3 | Due to plating Allowance |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Pre-Thread Dia. On Higher Side (Due to Plating Allowance) |
Root Cause Analysis (Outflow)
| Why 1 | M22 Threading No-go Pass observed at Customer End |
| Why 2 | Not observed during final inspection stage |
| Why 3 | No checkpoint at Final inspection |
| Why 4 | Sample basis inspection at PDI Stage |
| Why 5 | |
| Root Cause (Outflow) | Not Observed during Sample Basis Inspection. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Pre-Thread Dia taken on lower side upto 21 mm & 100% inspection added for M22x1-6H Go Gauge at Final. | Mr. Dnyaneshwar | 30/04/2022 | Completed | |
| Occurance | M22x1-6g threading gauge to be implemented on process side considering plating allowance. | Mr. Mohan Jadhav | 03/05/2022 | Completed | |
| Outflow | 100% Inspection at final stage. | Mr. Mohan Jadhav | 30/04/2022 | Completed | |
| Outflow | Pre-Thread Dia. Checking started and Dimension added in setup approval. | Mr. Mohan Jadhav | 30/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 1) Pre-Thread Dia. Checking started and Dimension added in First piece approval. 2) M22x1-6g threading gauge to be implemented on process side considering plating allowance after trial. 3) 100 % inspection of NOGO from both side entry thread. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | - |
10. Evidance of Countermeasure
| Occurance (Before) |
Pre-Thread Dia. on Higher Side. 79_Occurance_Before.jpeg |
| Occurance (After) |
Pre-thread dia. taken on lower side & 100% Go gauge inspection started in final inspection. 79_Occurance_After.jpeg |
| Outflow (Before) |
No Checkpoint at final stage/Sample basis inspection 79_Outflow_Before.xlsx |
| Outflow (After) |
Checkpoint added & OPL displayed at work station 79_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | CNC 9/Lock Nut/E92/93 |
12. Document Review
| Documents | ControlPlan, InspCheckSheet |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 300 |
| Reason for submission | Next 3 lots found ok |