QFR No - 8000795960
Defect Details
| NC No. | 8000795960 |
| NC Date | 18/07/2022 |
| NC Submission Date | |
| Part No. | F2KH02002B |
| Part Name | REBOUND SPRING -K74A |
| Supplier Name & Code | 101159-TECHNOMAT SPRINGS |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | DIAMETER OVER SIZE-OUTER DIA. OVERSIZE. |
1. Problem Description
| Defect Description | In K74 Rebound spring (F2KH02002B) observed wtih outer dia. oversize concern. OD oversize by 0.2 to 0.3 mm. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 10053 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@technomatsprings.com |
| Plant Head/CEO Email ID | technomatsprings@gmail.com |
| MD Email ID | patilsadanand@technomatsprings.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
15000
|
0
|
0
|
0
|
1200
|
16200
|
| Check Qty |
15000
|
0
|
0
|
0
|
1200
|
16200
|
| NG Qty |
10053
|
0
|
0
|
0
|
0
|
10053
|
| Scrap | 10053 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Check all material in house & customer end |
3. Process Flow
| Process Flow Description |
|---|
| RM>Coiling>B1>Grinding>shotpeening>B2>setting>visual inspection>oiling>Packing>Dispatch |
4. Process Details
| Process / Operation | Coiling |
| Outsource | No |
| Machine / Cell | CNC Coiling |
| Machine / Cell No. | Na |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled operator | Skill evaluation done (Training to be provided | X |
| Material | As per Drawing | RMTC checked found ok | O |
| Tool | Improper Tool Use | Check found ok | O |
| Machine | Coiling Machine | Found Ok | O |
| Method | Improper Material handling | Material handling done as per process verified found ok | 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 | 1000 |
7. Root Cause Analysis (Occurance)
| Why 1 | OD Over Size |
| Why 2 | Found OD over size 0.20 - 0.30 mm |
| Why 3 | Finger tool loose. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Finger tool loose |
Root Cause Analysis (Outflow)
| Why 1 | OD Over size |
| Why 2 | OD checking not done |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | OD Checking not done |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | OD Checking Start and training provide to visual inspection & Final inspection operator | Mrs.Renuka | 10/08/2022 | 02/08/2022 | Completed |
| Occurance | Training Provide to CNC operator. | Mr.Santosh | 02/08/2022 | 03/08/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | OD Checking Start |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1000/20 |
10. Evidance of Countermeasure
| Occurance (Before) |
OD Checking Frequency four hourly. 204_Occurance_Before.jpg |
| Occurance (After) |
OD Checking frequency change hourly basis & training provide to operator. 204_Occurance_After.jpg |
| Outflow (Before) |
OD checking not done at final inspection. 204_Outflow_Before.pdf |
| Outflow (After) |
OD checking start before dispatch. 204_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Rebound Spring |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 1500 |
| Reason for submission | Sustenance required. |