QFR No - 8000786394
Defect Details
| NC No. | 8000786394 |
| NC Date | 05/05/2022 |
| NC Submission Date | |
| Part No. | F2PH00902B |
| Part Name | VALVE RETAINER (C101B) |
| Supplier Name & Code | 101037-SHREE PATEL INDUSTRIES |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | NOT AS PER SPECIFICATION-CONCENTRICITY MORE (0.1) |
1. Problem Description
| Defect Description | Concentricity found out of specification (0.19, 0.18, 0.22, 0.26 mm against the spec of 0.1mm Max) due to which Facing fitment problem i.e. Part not passing Matting Parts |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 2211 |
| 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 |
14000
|
0
|
0
|
6000
|
0
|
20000
|
| Check Qty |
14000
|
0
|
0
|
6000
|
0
|
20000
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Hold the material at final stage and segregation done accordingly. |
3. Process Flow
| Process Flow Description |
|---|
| 10. Incoming RM 20. Parting 30. Facing and Chamfering 40. CNC ID turning & Facing 50. OD Grinding 60. Zink Plating 70. Inspection 80. Packing & Dispatch |
4. Process Details
| Process / Operation | CNC ID turning & Facing |
| Outsource | No |
| Machine / Cell | CNC M/C |
| Machine / Cell No. | M/C-10 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Clamping Pressure | During Gemba visit, clamping pressure of CNC m/c found inadequate | 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 | 05 |
7. Root Cause Analysis (Occurance)
| Why 1 | Concentricity found out of spec. |
| Why 2 | Concentricity generate out of spec. during CNC process. |
| Why 3 | Clamping pressure found inadequate during process. |
| Why 4 | Operator was not aware about the Clamping pressure specification. |
| Why 5 | No indication done on clamping pressure. |
| Root Cause (Occurance) | 1. Clamping pressure found inadequate during process. 2. No indication done on clamping pressure |
Root Cause Analysis (Outflow)
| Why 1 | Concentricity found out of spec. |
| Why 2 | Parts were not traced in final inspection . |
| Why 3 | Concentricity not checked during final inspection. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Concentricity not checked during final inspection. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Red and Green indication Marking done on Clamping Pressure dial to easily understand to operators. | Pradeep Tripathi | 16/05/2022 | 16/05/2022 | Completed |
| Outflow | Sampling inspection started for concentricity check. | Pradeep Tripathi | 16/05/2022 | 16/05/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No Change |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 |
10. Evidance of Countermeasure
| Occurance (Before) |
CP 88_Occurance_Before.xlsx |
| Occurance (After) |
CP 88_Occurance_After.xlsx |
| Outflow (Before) |
Sampling Plan 88_Outflow_Before.xls |
| Outflow (After) |
Sampling Plan 88_Outflow_After.xls |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | No |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Ok |