QFR No - 8000787719
Defect Details
| NC No. | 8000787719 |
| NC Date | 17/05/2022 |
| NC Submission Date | |
| Part No. | F1LG00902B |
| Part Name | SEAT PIPE -K86A |
| Supplier Name & Code | 100929-HARSHAD ENGINEERING COMPANY |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | HIGHT U/SIZE.-TOTAL LENGTH LESS ISSUE |
1. Problem Description
| Defect Description | K0LA seat pipe total length less issue |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | nqppngc1jzrocztqb5vn0rur.xlsx |
Supplier Communication Details
| Quality Head Email ID | qaharshad@miteshauto.com |
| Plant Head/CEO Email ID | mitesh@miteshauto.com |
| MD Email ID | auto.mitesh@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
4000
|
0
|
0
|
375
|
1100
|
5475
|
| Check Qty |
4000
|
0
|
0
|
375
|
1100
|
5475
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1. 100 % sorting done at ETL 2. 100 % sorting done by length gauge checking at HEC wip & FG stock |
3. Process Flow
| Process Flow Description |
|---|
| "10 - Raw Material Annealed and Phosphated "20-A - Cutting & 20-B- Cutting wt. "30-A MOS Application 30 -B Multistation Draw "40-A- Head Formation "40-B Inward/Incoming Inspection "50 - Rough Grinding "60-A CNC Head Turning , Facing. 60-B Facing & Boring 60-C Tapping "70A - Punching 70B-Chamfering "80-A - Finish grinding 80-B Buffing "90-A- De-burr 90-B- Final/Visual Inspection "100-A ID Cleaning Diesel 100-B - Ultrasonic cleaning "110-A- Visual Inspection at Q gate 110-B - Rust oil Application "120 - Packing & Dispatch |
4. Process Details
| Process / Operation | CNC |
| Outsource | No |
| Machine / Cell | CNC facing & drilling machine |
| Machine / Cell No. | 141, 144 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Improper loading during facing operation | improper loading | 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 | 50nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Total Length under size |
| Why 2 | Part loaded 2.0 mm offset while facing operation |
| Why 3 | while total length facing operation part not correctly loaded |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | while total length facing operation part not correctly loaded |
Root Cause Analysis (Outflow)
| Why 1 | Total Length undersize |
| Why 2 | total length skip from inspector |
| Why 3 | 100% inspection not done for total length |
| Why 4 | As per sampling inspection done |
| Why 5 | |
| Root Cause (Outflow) | 100% inspection not done for total length |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Training given to CNC operator for loading of parts | Kamil and Yogesh | 26/05/2022 | Completed | |
| Outflow | 100% inspection started for total length | Vaibhav Sirshat | 26/05/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection done for total length |
| 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) |
Sampling inspection for total length 124_Occurance_Before.pdf |
| Occurance (After) |
100% inspection for Total Length 124_Occurance_After.pdf |
| Outflow (Before) |
Not available 124_Outflow_Before.jpg |
| Outflow (After) |
Training and awareness given to inspector 124_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | CNC |
12. Document Review
| Documents | ControlPlan, WISOP |
| Specify Other Document | WI and C/P |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | reviewed 5000 no length issue found ok |