QFR No - 8000788086
Defect Details
| NC No. | 8000788086 |
| NC Date | 19/05/2022 |
| NC Submission Date | |
| Part No. | C3MD00402B |
| Part Name | COMPRESSION SPRING 64kg |
| Supplier Name & Code | 100185-HELICAL SPRINGS |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | MISSMATCH-WIRE DIA OBS 1.78 AGAINST 1.90+/-0.03MM |
1. Problem Description
| Defect Description | Wire dia observed 1.78 against 1.90+/-0.03 mm |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | Prabhat@helicalsprings.in |
| Plant Head/CEO Email ID | awadhwa@helicalsprings.in |
| MD Email ID | ataneja@helicalsprings.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
0
|
0
|
0
|
18000
|
0
|
18000
|
| Check Qty |
0
|
0
|
0
|
5000
|
0
|
5000
|
| NG Qty |
0
|
0
|
0
|
2
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation of material at helical end found no part NG |
3. Process Flow
| Process Flow Description |
|---|
| RM->COILING->SR1->GRINDING->SHOT -PEENING->SR2->FINAL INSPECTION->SURFACE FINISHING(OILING)->DESPATCH\PACKING |
4. Process Details
| Process / Operation | PACKING\DESPATCH |
| Outsource | No |
| Machine / Cell | NONE |
| Machine / Cell No. | NONE |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | NEW OPERATOR | NO NEW MANPOER.ALL MANPOWER MIN. 2 YEAR EXPERIENCED | O |
| Method | ERROR IN INSPECTION | WIRE DIA CHECK AT COILING STATION FOUND OK | O |
| Method | SIMILIAR PART MIXUP | LEF OUT PART OF WIRE DIA 1.90 STORE IN RACK AND 1.8 WIRE DIA IS ALSO STORE | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 10 |
7. Root Cause Analysis (Occurance)
| Why 1 | Wire dia 1.80 mm AGAINST 1.90MM (MIX-UP) |
| Why 2 | Different model Spring got mixed up during packing |
| Why 3 | Both springs are same in Geometrically |
| Why 4 | unidentified other model (left out parts) loose springs packed during packing. |
| Why 5 | All model Springs left out parts are store in single racks |
| Root Cause (Occurance) | unidentified other model (left out parts) loose springs packed during packing. |
Root Cause Analysis (Outflow)
| Why 1 | Wire dia 1.80 mm AGAINST 1.90MM (MIX-UP) |
| Why 2 | Wrong model mix -up |
| Why 3 | Could not detect during sampling inspection |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Could not detected in sampling plan |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1. Training given to oiling and packing person for how to handle the loose springs. 2.)Separate packing station to be defined for both the parts.(Under discussion) 3.) Diffrent Loaction is defiend to store the bothe parts (Under discussion) 4.) Display Similar parts list | Arunesh | 31/05/2022 | 30/05/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | no change is inspection method |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 20 |
10. Evidance of Countermeasure
| Occurance (Before) |
location not defined 129_Occurance_Before.jpg |
| Occurance (After) |
location defined 129_Occurance_After.jpg |
| Outflow (Before) |
wire dia not checking at final inspection 129_Outflow_Before.jpg |
| Outflow (After) |
wire dia checking at final inspection as per sampling 129_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | similar part matrix displayed |
12. Document Review
| Documents | PFMEA |
| Specify Other Document | Work instruction |
13. Effectiveness Of Action
| Reviewed Quantity | 50000 |
| Reason for submission | Inspection side action not full proof need 100% inspection for ID to catch wire dia variation |