QFR No - 8000790797
Defect Details
| NC No. | 8000790797 |
| NC Date | 10/06/2022 |
| NC Submission Date | |
| Part No. | F1DZ00902B |
| Part Name | FORK BOLT K86A |
| Supplier Name & Code | 100189-SANGKAJ STEEL PVT LTD. |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | OIL LEAKAGE-OIL LEAKAGE DUE TO FORK BOLT CENTER HOLE |
1. Problem Description
| Defect Description | K0YA Fort fork oil leakage through fork bolt compliant came from HMSI -3F because K86 fork bolt center hole available |
| Detection Stage | Customer End |
| Problem Severity | Function |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | maheshmishra@sangkaj.com |
| Plant Head/CEO Email ID | pardeshinr@sangkaj.com |
| MD Email ID | anirudh.2007@hotmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5000
|
0
|
0
|
2300
|
0
|
7300
|
| Check Qty |
5000
|
0
|
0
|
2300
|
0
|
7300
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All pipeline material 100% sagrigated and material keep aside for with identification marking. |
3. Process Flow
| Process Flow Description |
|---|
| 1.RM INWARD & INSPECTION - 2.TRAUB MACHINE CUTTING AND DRILL - 3.CNC 1ST SETUP - 4.CNC 2ND SETUP - 5.ACROSS FLAT MILLING - 6.DEBURRING - 7. PLATING -8.FINAL INSPECTION -9.DISPATCH |
4. Process Details
| Process / Operation | TRAUB MACHINING |
| Outsource | No |
| Machine / Cell | TRAUB SECTION |
| Machine / Cell No. | 52 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Machine condition is not ok | Machine condition is ok daily check sheet verified | O |
| Man | New manpower | Operator skilled and skill matrix verified. | O |
| Man | New operator | Operator is old | O |
| Man | Not aware about process | Manpower aware about process | O |
| Machine | Adjustment nut worn out & Loose | Adjustment nut worn out & Loose Found | X |
| Machine | Machine is not in working | Machine is in working condition | O |
| Method | Wrong judgment during visual | Judgement is wrong because marking is provided on centre of the fork bolt | X |
| Material | RM Damages | Material checked and found ok | O |
| Method | Wrong training | Correct training is provided | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
7. Root Cause Analysis (Occurance)
| Why 1 | Through hole observed in Fork Bolt K-86 |
| Why 2 | Excess depth of material cut |
| Why 3 | Drill travels more than its limit. |
| Why 4 | Adjustment nut of stopper was loose |
| Why 5 | Adjustment nut worn out |
| Root Cause (Occurance) | Adjustment nut worn out |
Root Cause Analysis (Outflow)
| Why 1 | Through hole observed in Fork Bolt K-86 |
| Why 2 | Skipped from final inspector during inspection |
| Why 3 | Judgement is wrong because marking is provided on center of the fork bolt. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Judgement is wrong because marking is provided on center of the fork bolt. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Stopper Adjustment nut replaced with new one. | Mr. Raut santosh | 13/06/2022 | 13/06/2022 | Completed |
| Occurance | Stopper double lock nut used for tightening. | Mr. Raut santosh | 13/06/2022 | 13/06/2022 | Completed |
| Outflow | Skip from inspection due to wrong judgment so awareness given to inspector. | Shende P | 10/06/2022 | 13/06/2022 | Completed |
| Occurance | Step drill used at semi finish stage to maintain drill depth size | Mr. Raut santosh | 11/06/2022 | 13/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NA |
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
10. Evidance of Countermeasure
| Occurance (Before) |
Adjustment nut worn out 169_Occurance_Before.pptx |
| Occurance (After) |
Stopper double lock nut used for tightening. 169_Occurance_After.pptx |
| Outflow (Before) |
Judgement is wrong because marking is provided on centre of the fork bolt . 169_Outflow_Before.xlsx |
| Outflow (After) |
Skip from inspection due to wrong judgment so awareness given to inspector. 169_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, WISOP, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |