QFR No - 8000790517
Defect Details
| NC No. | 8000790517 |
| NC Date | 08/06/2022 |
| NC Submission Date | |
| Part No. | F2DZ04603B |
| Part Name | FORK BOLT J1A & J1D |
| 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 |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 58 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | z00fl2pbvmq5dnlexw5yl2nz.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 |
100
|
5000
|
0
|
5000
|
0
|
10100
|
| Check Qty |
100
|
5000
|
0
|
5000
|
0
|
10100
|
| NG Qty |
10
|
0
|
0
|
0
|
0
|
10
|
| Scrap | 10 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| dot mark on head |
3. Process Flow
| Process Flow Description |
|---|
| 1.RAW MATERIAL 2.CUTTING 3.BUFFING 4.DRILLING&FACING 5.TAPPING 6.CNC TURNING 7.MILLING 8.BACK FACE BUFFING&MILLING BURR REMOVE 9.SURFACE TREATMENT 10.FINAL INSPECTION |
4. Process Details
| Process / Operation | threading op |
| Outsource | No |
| Machine / Cell | 202 |
| Machine / Cell No. | 2 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | MISHANDLING OF MATERIAL | DURING TRANSPORTATION 1 PIECE FELL DOWN FROM BIN AND THREAD GOT DAMAGE | O |
| Method | INSPECTION METHOD NOT EFFECTIVE | CHECKED AND VALIDATED ,FOUND EFFECTIVE | X |
| Material | RAW MATERIAL GRADE NOT OK | CHECKED AND VALIDATED ,FOUND OK | X |
| Tool | ROLLING DIE WEAR | CHECKED AND VALIDATED ,FOUND OK | X |
| Machine | NUT AND BOLTS OF MACHINE MAY LOOSE | CHECKED AND VALIDATED FOUND PROPERLY TIGHT | 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 Threading not ok |
| Why 2 | The problem occurred at transportation stage. |
| Why 3 | During transportation 1 piece fell down from bin and thread got damage. |
| Why 4 | Operator was new and put the N.G part along with the OK part bin. |
| Why 5 | So One piece of thread damage got mixed with finished material . |
| Root Cause (Occurance) | During transportation 1 piece fell down from bin and thread got damage. |
Root Cause Analysis (Outflow)
| Why 1 | M38 Threading not ok |
| Why 2 | Operator was not aware about this type of defect. |
| Why 3 | This type of problem came first time so the defected part skipped from detection. |
| Why 4 | So final inspector was not able to detect this problem. |
| Why 5 | So NG part dispatched to customer. |
| Root Cause (Outflow) | Operator was not aware about this type of 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 to handle the material with proper care. | NAVEEN | 08/06/2022 | 07/06/2022 | Completed |
| Outflow | Work instructions given to final inspector regarding the defect and to check the material with gauge before packing and dispatch. | UMED | 08/06/2022 | 07/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | no |
| 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) |
NOT AVAILABLE 171_Occurance_Before.pdf |
| Occurance (After) |
WORK INSTRUCTIONS 171_Occurance_After.pdf |
| Outflow (Before) |
NOT AVAILABLE 171_Outflow_Before.pdf |
| Outflow (After) |
WORK INSTRUCTIONS 171_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 | 100 |
| Reason for submission | As discussed with local representative Mr Ambhore Raosaheb- Plan for packaging improvement and share line of action through mail |