QFR No - 8000788179
Defect Details
| NC No. | 8000788179 |
| NC Date | 20/05/2022 |
| NC Submission Date | |
| Part No. | F2DZ07712B |
| Part Name | FORK BOLT J1D Ni-Cr plated |
| Supplier Name & Code | 101263-SINGLA PRECISION SCREWS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-M38 THREADING NOT OK |
1. Problem Description
| Defect Description | M38 Threading Not ok- GO gauge not qualify |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 99 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | jq1zd3jwbvlx5fndf34ouof2.pptx |
Supplier Communication Details
| Quality Head Email ID | quality@singlaprecision.com |
| Plant Head/CEO Email ID | quality@singlaprecision.com |
| MD Email ID | aditya@singlaprecision.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
2500
|
0
|
1000
|
1500
|
7000
|
| Check Qty |
2000
|
2500
|
0
|
1000
|
1500
|
7000
|
| NG Qty |
1
|
1
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% sorting done at warehouse and at supplier end 01 Ng piece found. |
3. Process Flow
| Process Flow Description |
|---|
| 1.R.M INSPECTION 2. PART OFF 3. ANEALING 4. PHOSPHATING 5. FORGING 6. HEX BUFFING 7. CNC 1ST 8. CNC 2ND 9. BUFFING 10. SURFACE TREATMENT 11. FINAL INSPECTION 12. PACKING. |
4. Process Details
| Process / Operation | TRANSPORTATION |
| Outsource | No |
| Machine / Cell | WAREHOUSE |
| Machine / Cell No. | 1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | DURING TRANSPORTATION 1 PIECE FELL DOWN FROM BOX AND THREAD GOT DAMAGE | VALIDATED | O |
| Method | INSPECTION METHOD NOT EFFECTIVE | VALIDATED AND FOUND OK | X |
| Tool | ROLLING DIE WEAR | VALIDATED AND FOUND OK | X |
| Machine | NUT BOLTS MAY LOOSE | VALIDATED AND FOUND PROPERLY TIGHT | X |
| Material | RAW MATERIAL GRADE NOT OK | VALIDATED AND FOUND OK | 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 | 50/1200 |
7. Root Cause Analysis (Occurance)
| Why 1 | M38 THREAD NOT OK |
| Why 2 | THE PROBLEM OCCURED AT TRANSPORTATION STAGE |
| Why 3 | DURING TRANSPORTATION 1 PIECE FELL DOWN FROM BOX AND THREAD GOT DAMAGE |
| Why 4 | OPERATOR WAS NEW AND PUT THE NG PART ALONG WITH THE OK PART BIN. |
| Why 5 | SO 1 PIECE OF THREAD DAMAGE GOT MIXED WITH FINISHED MATERIAL |
| Root Cause (Occurance) | DURING TRANSPORTATION 1 PIECE FELL DOWN FROM BOX AND THREAD GOT DAMAGE. |
Root Cause Analysis (Outflow)
| Why 1 | M38 THREAD NOT OK |
| Why 2 | OPERATOR WAS NEW AND NOT AWARE ABOUT THIS DEFECT |
| Why 3 | THIS TYPE OF PROBLEM CAME FIRST TIME SO THE DEFECTED PART SKIPPED FROM INSPECTION |
| Why 4 | SO FINAL INSPECTOR WAS NOT ABLE TO DETECT THE PROBLEM |
| Why 5 | SO NG PART DISPATCHED TO CUSTOMER |
| Root Cause (Outflow) | OPERATOR WAS NEW AND NOT AWARE ABOUT THIS DEFECT. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | WORK INSTRUCTIONS GIVEN TO OPERATOR ABOUT THE DEFECT AND HANDLE THE MATERIAL WITH PROPER CARE. | RAJU | 14/05/2022 | 21/05/2022 | Completed |
| Outflow | WORK INSTRUCTIONS GIVEN TO OPERATOR ABOUT THE DEFECT AND TO CHECK THE MATERIAL WITH GAUGE BEFORE PACKING AND DISPATCH. | UMED | 14/05/2022 | 21/05/2022 | Completed |
| Occurance | EARLIER THE MATERIAL WAS PACKED IN BOX AND PIECES WERE IN LOOSE POSITION . NOW WE STARTED PACKING THE MATERIAL IN STANDARDS BINS. SO AS TO PREVENT THE MATERIAL FROM DENT AND DAMAGES | RAJU | 13/05/2022 | 21/05/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NO CHANGE |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 50/1200 |
10. Evidance of Countermeasure
| Occurance (Before) |
MATERIAL WAS PACKED IN LOOSE POSITION IN BOXES 131_Occurance_Before.jpeg |
| Occurance (After) |
STANDARD BINS ARE STARTED FOR PACKING. 131_Occurance_After.jpeg |
| Outflow (Before) |
NOT AVAILABLE 131_Outflow_Before.pdf |
| Outflow (After) |
WORK INSTRUCTIONS 131_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NOT APPLICABLE |
12. Document Review
| Documents | WISOP |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |