QFR No - 8000793197
Defect Details
| NC No. | 8000793197 |
| NC Date | 27/06/2022 |
| NC Submission Date | |
| Part No. | S1GD01726B |
| Part Name | INNER TUBE CHAMFERED K0LA |
| Supplier Name & Code | 100165-SAPTAGIRI INDUSTRIES |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | HIGHT O/SIZE.-TOTAL LENGTH LESS&MORE |
1. Problem Description
| Defect Description | inner tube total length less issue |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 121 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | 1aq54fznl1qpruyaavnfmmtb.xlsx |
Supplier Communication Details
| Quality Head Email ID | quality@saptagirigroup.in |
| Plant Head/CEO Email ID | production@saptagirigroup.in |
| MD Email ID | argandhi@saptagirigroup.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
3000
|
2000
|
0
|
0
|
2000
|
7000
|
| Check Qty |
3000
|
2000
|
0
|
0
|
2000
|
7000
|
| NG Qty |
2
|
0
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % verify all material at all location and observed 02 nos NG |
3. Process Flow
| Process Flow Description |
|---|
| RM receipt & Inspection , Cutting , Chamfer at both end , Straightness inspection , Packing |
4. Process Details
| Process / Operation | Tube Cutting |
| Outsource | No |
| Machine / Cell | Troub machine |
| Machine / Cell No. | Troub machine 04 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Total length checking special gauge ware out | Gauge verified by height gauge and its observed ok | O |
| Machine | Set up part mix up with OK material | Red bin with lock and key it’s missing at the machine | O |
| Machine | Stopper locking loosed while tube cutting | Not loosed the stopper while tube cutting | O |
| Machine | End piece mix up with OK material | For storing end pieces one gunny bag available with identified | O |
| Method | Length checking not done adequately | Length checking done adequality | O |
| Man | Inspector not aware about total length | Operator and inspector nor a aware about the total length special gauge and its operating | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Total length U/s |
| Why 2 | Set up part mix up with OK material |
| Why 3 | Set up part storing bin missing |
| Why 4 | No Lock & Key for storing set up or rejected parts |
| Why 5 | |
| Root Cause (Occurance) | No Lock & Key for storing set up or rejected parts |
Root Cause Analysis (Outflow)
| Why 1 | Total length U/s |
| Why 2 | Operator not aware about total length |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Operator not aware about total length |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | ) Provide Lock & key Rejection storage bin | Mr. Munja Hore | 29/06/2022 | 30/06/2022 | Completed |
| Occurance | ) Provide the stopper slot on chamfer machine | Mr. Munja Hore | 29/06/2022 | 30/06/2022 | Completed |
| Occurance | ) Make SOP for Tube Cutting operation & its verification | Mr. Munja Hore | 29/06/2022 | 30/06/2022 | Completed |
| Outflow | Verify Gauge Length. Started 100% inspection for length verification. | Mr. Munja Hore | 29/08/2022 | 30/06/2022 | Completed |
| Outflow | Awareness Training given to concern operator & Inspector | Mr. Munja hore | 29/08/2022 | 30/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % inspection started by special total length gauge |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Set part storage bin missing ( Not available at machine ) , no lock & key equipment for keeping rejection or set up piece 190_Occurance_Before.pdf |
| Occurance (After) |
Provided lock & key equipment for keeping rejection or set up piece 190_Occurance_After.pdf |
| Outflow (Before) |
Inspector not aware about total length and checking method 190_Outflow_Before.pdf |
| Outflow (After) |
Awareness training given to concern inspector & OPL display at work place ,
Made SOP for length checking gauge and same awareness given 190_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Other machine operator and inspector |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | Control plan |
13. Effectiveness Of Action
| Reviewed Quantity | 12600 |
| Reason for submission | Effectiveness monitored 4 lots and no defect repeated |