QFR No - 8000787300
Defect Details
| NC No. | 8000787300 |
| NC Date | 12/05/2022 |
| NC Submission Date | |
| Part No. | 520FG07802 |
| Part Name | GEAR PRIMARY DRIVEN (JZ) |
| Supplier Name & Code | 100987-FLASH VIVEN MACHINING TECHNOLO |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | MIX UP OTHER MODEL-MIXUP GEAR 74 TEETH AGAINST 75 TEETH |
1. Problem Description
| Defect Description | MIX UP OTHER MODEL-MIXUP GEAR 74 TEETH AGAINST 75 TEETH |
| Detection Stage | Customer End |
| Problem Severity | Fitment |
| NG Quantity | 7 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | sgn.quality@flashgroup.in |
| Plant Head/CEO Email ID | dkj.mfg@flashgroup.in |
| MD Email ID | sv.md@flashgroup.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
1000
|
0
|
2000
|
800
|
5800
|
| Check Qty |
2000
|
1000
|
0
|
2000
|
800
|
5800
|
| NG Qty |
10
|
0
|
0
|
0
|
0
|
10
|
| Scrap | 10 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Check pipeline material with White dot marking on gear Face |
3. Process Flow
| Process Flow Description |
|---|
| CNC-Hobbing-HT-Bore Honning-Teeth Honning-Final Inspection-Packing-Dispatch |
4. Process Details
| Process / Operation | Dispatch |
| Outsource | No |
| Machine / Cell | Dispatch |
| Machine / Cell No. | Dispatch |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Part Mix up | Yes | X |
6. Inspection Method Analysis (Current)
| Inspection Method | 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 | Mix-up of two parts JE551427 & JZ551400. During Final packaging operation |
| Why 2 | Packing of part no JE551427 & JZ551400 at the same location . |
| Why 3 | Separate location not defined |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Partwise separate location not defined |
Root Cause Analysis (Outflow)
| Why 1 | Part not capture at Packing area |
| Why 2 | No awareness |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | 1. Visual Inspection & Input inspected Parts not identified. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1.Partwise separation location to be defined to avoided part mix-up. | RBP/AD | 12/05/2022 | 12/05/2022 | Completed |
| Outflow | 1. After Inspection identification will be provided (color code) 2. Inspection table separately, similar part inspection are defined different location. 3. OPL & Q alert Displayed | AD | 10/05/2022 | 12/05/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection table separately, similar part inspection are defined different location. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
1. Partwise separate location not defined 108_Occurance_Before.xlsx |
| Occurance (After) |
1.Partwise separation location to be defined to avoided part mix-up. 108_Occurance_After.xlsx |
| Outflow (Before) |
1. Visual Inspection
& Input inspected Parts not identified. 108_Outflow_Before.xlsx |
| Outflow (After) |
1. After Inspection identification will be provided (color code)
2. Inspection table separately, similar part inspection are defined different location.
3. OPL & Q alert Displayed 108_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | JZ & PF model |
12. Document Review
| Documents | ProcessFlowChart, PackingStd |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | ok |