QFR No - 8000787777
Defect Details
| NC No. | 8000787777 |
| NC Date | 17/05/2022 |
| NC Submission Date | |
| Part No. | F2BF05707M |
| Part Name | OUTER TUBE P/C RH (HMS-30) |
| Supplier Name & Code | 101219-ROCKMAN INDUSTRIES |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | THREADING MISSING-HALF THREAD OBSERVED IN FENDER HOLE |
1. Problem Description
| Defect Description | M6 Thread missing in fender hole |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | 0odo1tillahsmzo20nbc3tx5.jpg |
Supplier Communication Details
| Quality Head Email ID | shriknat.sharma@rockman.in |
| Plant Head/CEO Email ID | mlshah@rockman.in |
| MD Email ID | skmishra2@rockman.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
500
|
0
|
0
|
500
|
0
|
1000
|
| Check Qty |
500
|
0
|
0
|
500
|
0
|
1000
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Immediately segregate all the stock at M/s Endurance end and M/s Rockman end also , |
3. Process Flow
| Process Flow Description |
|---|
| Casting - Gate Cutting /Buffing - Machining - Buffing - Leakage testing - washing - Inspection - Painting - Inspection and dispatch |
4. Process Details
| Process / Operation | Machining process |
| Outsource | No |
| Machine / Cell | machining cell |
| Machine / Cell No. | 1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | dedicated machine are not in used | verified and found dedicated machined are being used fro the part | O |
| Method | Pat wrong load in the machine | part loading in OK condition | O |
| Material | wrong material used during casting | verified and found OK | O |
| Man | New manpower deoute | Skilled manpower used on the machining center | O |
| Tool | tool become worn out | verified and found tool become worn out | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
7. Root Cause Analysis (Occurance)
| Why 1 | Drill Length Less. |
| Why 2 | Home position missed by machine |
| Why 3 | Home position memory forget after some time |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Home Position forget after some time |
Root Cause Analysis (Outflow)
| Why 1 | Part skipped from final Inspection |
| Why 2 | check point not given to Operator |
| Why 3 | earlier there is no any check point added in the system |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | earlier there is no any check point added in the system |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Tapping Check as per sampling Plan Hourly monitoring at generation stage | Production | 16/06/2022 | 15/06/2022 | Completed |
| Occurance | Machine CMOS changed | lalit | 16/06/2022 | 15/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Hourly monitoring started at machine shop |
| 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) |
not applicable 122_Occurance_Before.pdf |
| Occurance (After) |
not available 122_Occurance_After.pdf |
| Outflow (Before) |
not applicable 122_Outflow_Before.pdf |
| Outflow (After) |
Photo attached 122_Outflow_After.bmp |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | CMOS changed on all the machine |
12. Document Review
| Documents | |
| Specify Other Document | no change |
13. Effectiveness Of Action
| Reviewed Quantity | 200 |
| Reason for submission | Repeated issue observed in every month |