QFR No - 8000788173
Defect Details
| NC No. | 8000788173 |
| NC Date | 20/05/2022 |
| NC Submission Date | |
| Part No. | 550BZ01402 |
| Part Name | CAP OIL LOCK - DF01 |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-OD OVERSIZED DIMN 7MM OVERSIZE STEP ON T |
1. Problem Description
| Defect Description | OD 18mm oversized by 0.15mm & Dimn 7mm Undersized/oversized |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 3158 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | jq1zd3jwbvlx5fndf34ouof2.pptx |
Supplier Communication Details
| Quality Head Email ID | quality@apw3.co.in |
| Plant Head/CEO Email ID | kurund.ma@sharp-engineers.com |
| MD Email ID | urkhandelwal@sharp-engineers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5000
|
0
|
0
|
5000
|
6000
|
16000
|
| Check Qty |
5000
|
0
|
0
|
5000
|
6000
|
16000
|
| NG Qty |
3158
|
0
|
0
|
0
|
15
|
3173
|
| Scrap | 8 |
| Rework | 3165 |
| Under Deviation | 0 |
| Containment Action |
|---|
| On job training given to operator & lock and key box provided for setting pieces. OPL displayed on machine stage for awareness purpose. |
3. Process Flow
| Process Flow Description |
|---|
| 10)- RM Inward inspection, 20)- Parting ,Drilling & angle 1.4°, 30)- Ø8.50 & Ø14.04 chamfering, 40)-Grinding Operation,50)-Plating, 60)-Final Inspection, 70)-Pre-dispatch inspection., 80)-Packing & Dispatch. |
4. Process Details
| Process / Operation | Parting and drilling operation. |
| Outsource | No |
| Machine / Cell | Traub Machining shop |
| Machine / Cell No. | SE/A/05 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Wrong material used | Raw material test certificate verified by in process quality engineers & Third part report evident. | O |
| Method | Setting piece mix up | Setting pieces got mix up with ok material, Lock and key not exist for Rework and rejection parts. | X |
| Machine | Inaccurate machine | Preventive maintenance monitoring on half yearly basis & record evident as per plan | O |
| Man | semi-skilled manpower, operator fluctuation | Operator having inadequate knowledge of operation & Rework/Rejection part disposal | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
7. Root Cause Analysis (Occurance)
| Why 1 | Depth 7.0+/-0.1 O/s |
| Why 2 | Setting piece mix up |
| Why 3 | Lock & Key not done for setting pieces |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Lock & Key not done for setting pieces |
Root Cause Analysis (Outflow)
| Why 1 | Judgment error |
| Why 2 | Checking By PPG |
| Why 3 | Special dial type gauge not available. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Special dial type gauge not available. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | On job training given to operator & lock and key box provided for setting pieces. OPL displayed on machine stage for awareness purpose. | Mr. Shaikh Laik | 25/05/2022 | 26/05/2022 | Completed |
| Outflow | Dial type gauge made available & Stage wise skill matrix monitoring and Q gate license implemented for inspectors. OPL displayed for awareness . | Mr. Shaikh Laik | 25/05/2022 | 26/05/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | M/s Sharp made available Spl. Dial type gauge for DIM 7.0+/-0.1 mm checking at final & in process inspection stage to avoid man oriented inspection. Gauge implemented & checking on daily basis. |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 100:1200 |
10. Evidance of Countermeasure
| Occurance (Before) |
Lock & Key not done for setting pieces, Open red and yellow bin provided for setting/NG pieces. 130_Occurance_Before.pptx |
| Occurance (After) |
Rejection & Rework material kept in lock & key on machine to avoid mix up issue. 130_Occurance_After.pptx |
| Outflow (Before) |
1. Relation gauge used for checking 100% parts but not effective by vernier caliper, Detection side inspection being done by attribute type gauge. 130_Outflow_Before.pptx |
| Outflow (After) |
M/s Sharp made available Spl. Dial type gauge for DIM 7.0+/-0.1 mm checking at final & in process inspection stage to avoid man oriented inspection. Gauge implemented & checking on daily basis. 130_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | CAP OIL LOCK LML/DF & PRF |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | NIL |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | Ok |