QFR No - 8000799248
Defect Details
| NC No. | 8000799248 |
| NC Date | 09/08/2022 |
| NC Submission Date | |
| Part No. | 520DZ00212 |
| Part Name | FORK BOLT K60-(DS181012) |
| Supplier Name & Code | 101263-SINGLA PRECISION SCREWS |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | THREADING NOT OK-CHIPS IN M10 THREAD |
1. Problem Description
| Defect Description | Chips in M10 thread |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 50 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
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 |
1400
|
2000
|
0
|
0
|
1500
|
4900
|
| Check Qty |
1400
|
2000
|
0
|
0
|
1500
|
4900
|
| NG Qty |
500
|
0
|
0
|
0
|
0
|
500
|
| Scrap | 0 |
| Rework | 500 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % gauge inspection done at warehouse and supplier end. |
3. Process Flow
| Process Flow Description |
|---|
| 1. RM INSPECTION. 2. CNC TURNING 3. TAPPING 4. RETAPPING 5. THREAD ROLLING 6. PLATING. FINAL INSPECTION 7. PACKING |
4. Process Details
| Process / Operation | TAPPING |
| Outsource | No |
| Machine / Cell | TAPPING MACHINE |
| Machine / Cell No. | 2 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | tool wear | checked and validated tool life is effective | O |
| Material | material was not of required grade and size | checked and validated that material was of same grade and size | O |
| Machine | machine is not in good condition | checked and found machine is in good working condition | O |
| Method | Chips stuck in I.D during tapping process | validated and found I.D was not clear | X |
| Man | unskilled labour | checked and validated operator was skilled | O |
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 | Go gauge not qualify in M10 Thread |
| Why 2 | Chips were formed in M10 I.D during Tapping process and not removed |
| Why 3 | Chips were fold and stuck in M10 I.D and were not visible |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Chips were formed in M10 I.D during Tapping process and not removed. Chips were fold and stuck in M10 I.D and were not visible. |
Root Cause Analysis (Outflow)
| Why 1 | Go gauge not qualify in M10 Thread |
| Why 2 | Defected Part not detected in final inspection stage |
| Why 3 | Inspection was done according to sample plan |
| Why 4 | Defected parts skipped from inspection |
| Why 5 | Inspection was done according to sample plan |
| Root Cause (Outflow) | Inspection was done according to sample plan |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Additional process of Re -tapping check added in control plan | Ganesh Maurya | 19/08/2022 | 19/08/2022 | Completed |
| Outflow | 100% Retapping check done after Plating process to prevent the defect | Naveen | 19/08/2022 | 19/08/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Additional process of 100% Retapping check added |
| Inspection Method | Other |
| Other Inspection Method | Retapping check m/c |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 50/1200 |
10. Evidance of Countermeasure
| Occurance (Before) |
NOT AVAILABLE 224_Occurance_Before.pdf |
| Occurance (After) |
ADDITONAL PROCESS OF RETAPPING CHECK ADDED IN CONTROL PLAN 224_Occurance_After.pdf |
| Outflow (Before) |
NOT AVAILABLE 224_Outflow_Before.pdf |
| Outflow (After) |
100% RETAPPING CHECK DONE TO PREVENT THE DEFECT 224_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NOT APPLICABLE |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | Do correction in why-why analysis |