QFR No - 8000797760
Defect Details
| NC No. | 8000797760 |
| NC Date | 29/07/2022 |
| NC Submission Date | |
| Part No. | 550HL00602 |
| Part Name | OIL LOCK COLLAR |
| Supplier Name & Code | 100503-DIVYA INDUSTRIES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-LENGTH U/S, OD O/S, EXTRA HOLE |
1. Problem Description
| Defect Description | TOTAL LENGTH UNDERSIZED, O/D OVERSIZED & EXTRA HOLE PUNCHING |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 4 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@mahavirind.co.in |
| Plant Head/CEO Email ID | production@mahavirind.co.in |
| MD Email ID | rajesh@mahavirind.co.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
600
|
0
|
0
|
0
|
0
|
600
|
| Check Qty |
600
|
0
|
0
|
0
|
0
|
600
|
| NG Qty |
4
|
0
|
0
|
0
|
0
|
4
|
| Scrap | 4 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Suspected material Segregation at customer End |
3. Process Flow
| Process Flow Description |
|---|
| RM Inward- Store- Traub Parting - Semi finish Inward CNC-1st- CNC-2nd- Cross Hole Both sides- Deburring - OD Grinding - Plating -Final Inspection- Packing - Transport- |
4. Process Details
| Process / Operation | Cross Hole Both sides |
| Outsource | Yes |
| Machine / Cell | Cross Hole Drilling Machine |
| Machine / Cell No. | Drill M/C No.1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | During Cross hole Setting Piece Mix | During Cross Hole Drill CD distance Setiing 2pieces By mistake mix with ok material . | X |
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 | 100 |
7. Root Cause Analysis (Occurance)
| Why 1 | Double Cross hole |
| Why 2 | Setting defective pcs mix with OK Material |
| Why 3 | During the Change over CD Adjustment setting pcs mix |
| Why 4 | Cross drill operator Semiskilled |
| Why 5 | |
| Root Cause (Occurance) | Setting defective pcs mix with OK Material |
Root Cause Analysis (Outflow)
| Why 1 | Double Cross hole |
| Why 2 | Visual Inspection Not checking carefully |
| Why 3 | Depend On Cross Drill Operator |
| Why 4 | Without Identified Material Dispatch To Customer |
| Why 5 | |
| Root Cause (Outflow) | Without Identified Material Dispatch To Customer |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 1)Location Decided for Cross Hole Setting Piece and Defective Material. 2) Training To Operator. 3)Both Hole Identification Start By block marker | Mr.Suresh Kapgate/Mr.Pralhad Bhawar | 12/08/2022 | 12/08/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | After 360° Visual Inspection Identification Start to both cross hole to final Inspection Stage. |
| Inspection Method | Other |
| Other Inspection Method | VISUAL |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
10. Evidance of Countermeasure
| Occurance (Before) |
By Mistekly Setting Piece Mix With ok cross Hole Process Material. 215_Occurance_Before.jpg |
| Occurance (After) |
1) Quality Alert Display .2)Training To Operator .3)Lock & key Red Box Provide on Cross hole Drill Machine. Not Need More Change In Fixture. 215_Occurance_After.jpg |
| Outflow (Before) |
Without Identification Dispatch To Customer 215_Outflow_Before.jpeg |
| Outflow (After) |
1)100% Identification to both holes at the Final inspection Stage.2)Defected Sample Display On final Inspection Table. 3)Training To Inspector. 215_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All OLC Cross Hole Identification at the final Inspection stage Before Dispatch to the Customer |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | No Need |
13. Effectiveness Of Action
| Reviewed Quantity | 300 |
| Reason for submission | Verified next 3 lot and found ok |