QFR No - 8000788445
Defect Details
| NC No. | 8000788445 |
| NC Date | 23/05/2022 |
| NC Submission Date | |
| Part No. | F2GN02302B |
| Part Name | MAIN SPRING-KTEM/KTEL |
| Supplier Name & Code | 101225-HELICAL SPRINGS |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | MIX UP OTHER MODEL-MIXUP WITH OTHER MODEL |
1. Problem Description
| Defect Description | Other model mix-up concern. This is repetitive concern in other models supplied by M/s Helical Spring. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 702 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | k45nr4nswe1z3gj1mejw5zia.jpg |
Supplier Communication Details
| Quality Head Email ID | arun@helicalsprings.in |
| Plant Head/CEO Email ID | shaikhmoin@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 |
2794
|
0
|
0
|
2000
|
0
|
4794
|
| Check Qty |
2794
|
0
|
0
|
2000
|
0
|
4794
|
| NG Qty |
741
|
0
|
0
|
0
|
0
|
741
|
| Scrap | 0 |
| Rework | 741 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Inspection all material at ETL,WH & FG |
3. Process Flow
| Process Flow Description |
|---|
| Raw Material Receipt & Inspection, Coiling, Stress Relieving, End Grinding, Shot Peening, Scragging, Length & Waviness checking, Strain-aging, Surface Finish- Oiling, Final Inspection/ PDI, Packing, Dispatch. |
4. Process Details
| Process / Operation | Final Inspection |
| Outsource | No |
| Machine / Cell | NA |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Improper Material handling | Material handling done as per process verified found not ok | X |
| Man | unskilled Operator | Skill matrix checked found not ok | X |
| Machine | Machine check Sheet not followed | CLIT verified found Ok | O |
| Material | Material Grade | RMTC verified found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1000/19 |
7. Root Cause Analysis (Occurance)
| Why 1 | Other model mix up |
| Why 2 | Similar model springs storage location found at one place |
| Why 3 | Separate location not defined |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Separate location not defined |
Root Cause Analysis (Outflow)
| Why 1 | Other model mix up |
| Why 2 | Other model spring not detected during PDI inspection |
| Why 3 | PDI done on sampling basis |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | PDI done on sampling basis |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Separate Pallets defined for keeping similar models | Mr.Dadasaheb Mhaske | 01/06/2022 | 31/05/2022 | Completed |
| Occurance | Training provides to loading people & store team | Mr.Anuj Shelke | 01/06/2022 | 31/05/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No change |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 1000/19 |
10. Evidance of Countermeasure
| Occurance (Before) |
Separate location not defined 146_Occurance_Before.jpg |
| Occurance (After) |
Separate Pallets defined for keeping similar models 146_Occurance_After.pdf |
| Outflow (Before) |
PDI done on sampling basis 146_Outflow_Before.jpg |
| Outflow (After) |
PDI doing on sampling basis. Training provided to loading people & store team to keep similar type of springs on separate pallets 146_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Similar Model springs |
12. Document Review
| Documents | WISOP |
| Specify Other Document | SOP |
13. Effectiveness Of Action
| Reviewed Quantity | 150 |
| Reason for submission | Completed. |