QFR No - 8000788016
Defect Details
| NC No. | 8000788016 |
| NC Date | 19/05/2022 |
| NC Submission Date | |
| Part No. | F2FA19033M |
| Part Name | K0PG FORK PIPE MACHINED |
| Supplier Name & Code | 101109-TUBE INVESTMENTS OF INDIA LIMI |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | NOT AS PER SPECIFICATION-MACHINING OPERATION(46.1+01MM DEPTH MISS |
1. Problem Description
| Defect Description | Caulking Side (46.1 +0.1 mm Depth) Machining Operation Miss. |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | anandms@tii.murugappa.com |
| Plant Head/CEO Email ID | vijayakumarv@tii.murugappa.com |
| MD Email ID | mukeshahuja@tii.murugappa.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2010
|
0
|
0
|
1500
|
700
|
4210
|
| Check Qty |
2010
|
0
|
0
|
1500
|
700
|
4210
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1.100% Inspection Done at ETL end for all available Qty. 2.100% visual Inspection done for all available Qty of Machined Tubes KOPG & K86 - A Model with Blue Marking at Tube ID Chamfer at TI Sanand WH. |
3. Process Flow
| Process Flow Description |
|---|
| Incoming Material - Inward Inspection - Storage - CNC Machining Clip Side - CNC Machining Caulking Side - Drilling - Deburring - Final Inspection - Packing in Bins - Dispatch to ETL. |
4. Process Details
| Process / Operation | CNC Machining Caulking Side |
| Outsource | No |
| Machine / Cell | CNC Machining Cell |
| Machine / Cell No. | ACE CNC -02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Wrong Setup | Verified through Gemba observation and found M/c Setup Repot OK. | O |
| Machine | Machining Parameter | Verified through Gemba observation and found all Machine Parameter as per Control Plan | O |
| Method | Incomplete M/C Cycle | Verified through Gemba observation and found that if Sudden power Failure / Sudden Emergency Button | X |
| Machine | Sudden Machine Breakdown | Verified through Gemba &facts found ACE CNC -02 M/c Stop frequently with error cabinet temp too high | X |
| Man | Inspection SOP not Followed | in Deburring Fixture Pokayoke , fully Inserted & rest at bottom Plate is not easily to visualize. | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Pokayoke |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 20 Nos/lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Caulking Depth of Dim. 46.10 +.10 mm Miss part found at Customer end. |
| Why 2 | Incomplete Machining cycle |
| Why 3 | ACE CNC -02 Machine Stopping in Running operation |
| Why 4 | ACE CNC -02 m/c stopping with error cabinet temp too high. |
| Why 5 | In ACE CNC -02 Machine Setting ( Handy ) value of Parameter write is wrong ( set by Manufacturer ) |
| Root Cause (Occurance) | In ACE CNC -02 Machine Setting ( Handy ) value of Parameter write is wrong ( set by Manufacturer ) |
Root Cause Analysis (Outflow)
| Why 1 | Caulking Depth of Dim. 46.10 +.10 mm Miss part found at Customer end. |
| Why 2 | Part not Capture in De- Burring Fixture Poka-yoke ( at Bottom Side Bush Provided with OD 26 mm & Height 45 mm.) |
| Why 3 | Operator not judged Part is fully Inserted & rest at bottom of Deburring Poka-yoke Fixture. |
| Why 4 | Deburring Fixture poka-yoke Table Height is Less (380 mm ) & Burr Collecting box height ( 285 mm ) is More. |
| Why 5 | |
| Root Cause (Outflow) | Deburring Fixture poka-yoke Table Height is Less (380 mm ) & Burr Collecting box height ( 285 mm ) is More. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | After Discussion with ACE CNC M/C representative in Machine Setting ( Handy ) value of Parameter write changed from 1 to 0 | Mr. Bhupender Paji | 23/05/2022 | 22/05/2022 | Completed |
| Outflow | Training given to operator to check for Power Failure / Sudden stop of machine during operation part 100% for all Dimension and if part is not as per specification then the reject part. | Mr. Bhupendra. | 20/09/2022 | 20/09/2022 | Completed |
| Outflow | Deburring Poka-yoke Fixture table Height will Increase to 4 feet & Burr Collecting box height reduced to 50 mm | Mr. Palak Shah | 27/05/2022 | 26/05/2022 | Completed |
| Outflow | Deburring Work Instruction Updated for tube should be rested fully to bottom. | Mr.Piyush Parmar | 24/09/2022 | 23/09/2022 | Completed |
| Outflow | One Point Lesson Displayed at Deburring Station | Mr. Piyush Parmar | 24/09/2022 | 23/09/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Added Visual Check for Operation Miss with Identification marking in Caulking ID. |
| Inspection Method | Other |
| Other Inspection Method | Visual Insp. |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
In ACE CNC -02 Machine Setting ( Handy ) value of Parameter write is 1 due to this Machine stop in running with showing error of cabinet temp too high. 135_Occurance_Before.pdf |
| Occurance (After) |
To overcome the issue of cabinet temp too high resulting in machine Stoppage in Running in Machine Setting ( Handy ) value of Parameter write changed from 1 to 0 135_Occurance_After.pptx |
| Outflow (Before) |
Operator not able detected that Part is fully Inserted & rest at bottom of Deburring Poka- Yoke Fixture Cause of Deburring Fixture Table Height is Less (380 mm ) & Burr Collecting box height ( 285 mm ) is More. 135_Outflow_Before.pptx |
| Outflow (After) |
Deburring Poka-yoke Fixture table Height will Increase to 4 feet & Burr Collecting box height reduced to 50 mm .
So Operator will easily detect that Part is fully Inserted & rest at bottom of Deburring Poka-yoke Fixture. 135_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | ACE CNC -01 Machine TFF Tube Model - K86 -A |
12. Document Review
| Documents | WISOP |
| Specify Other Document | one Point Lesson |
13. Effectiveness Of Action
| Reviewed Quantity | 14000 |
| Reason for submission | Operation miss part not reported again in review qty. |