QFR No - 8000802161
Defect Details
| NC No. | 8000802161 |
| NC Date | 29/08/2022 |
| NC Submission Date | |
| Part No. | 520FN04002 |
| Part Name | HOLDER CLUTCH |
| Supplier Name & Code | 100150-DHANANJAY ENTERPRISES |
| ETL Plant | 1135-ETL 7/10 P Nagar |
| Defect Details | DIMN.O/SIZE.-ID OVERSIZE |
1. Problem Description
| Defect Description | ID OVERSIZE/UNDER SIZE ISSUE. |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 3 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qade@dhananjaygroup.com |
| Plant Head/CEO Email ID | gunjalvs@dhananjaygroup.com |
| MD Email ID | kandakuretn@dhananjaygroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
0
|
0
|
0
|
0
|
2000
|
| Check Qty |
2000
|
0
|
0
|
0
|
0
|
2000
|
| NG Qty |
3
|
0
|
0
|
0
|
0
|
3
|
| Scrap | 3 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregate the whole lot at the ETL End/DEPL End |
3. Process Flow
| Process Flow Description |
|---|
| Blanking/Piercing_Deburring_Chamfering_CNC Machining_Final Inspection_Cleaning_Dispatch |
4. Process Details
| Process / Operation | CNC Machining |
| Outsource | No |
| Machine / Cell | CNC Machining |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | in final inspection Air Plug gauge Skipped by the inspector | as final inspection (Air Plug Gauge Not done 100%) as Air Plug gauge Unit is under calibration | O |
| Machine | In Deburring no contribution for hole oversize | No Contribution | X |
| Tool | In Blanking/Piercing Premachining Hole | We have verified after blanking operation Premachining hole is ok | X |
| Method | In Machining its chance to mix up the part (Setting Part/Rework part) | Yes its having possibility to mixup the rejected parts (Setting Parts)at machine stage | 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 | In CNC machining ID Oversize by 0.2 |
| Why 2 | 100% Air Gauge parts not checked |
| Why 3 | Setting Part get mix up by operator |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Due to there is no Red Bin Available at machine stage so Rejected parts get mixed up |
Root Cause Analysis (Outflow)
| Why 1 | As 100% Air Plug gauge Checking at Final Stage as well as Machine stage |
| Why 2 | 100% Plug gauge not Done for final inspection |
| Why 3 | As Air gauge unit is under Calibration so that 100% inspection not done at final stage |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | As Air Gauge Unit is under calibration so that 100% inspection not done at final stage |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Now we have kept Red bin with lock and key for rejection parts (Set up /rework parts) | Mr. Gaurav Nikam | 05/09/2022 | Completed | |
| Outflow | Duble Ended Plain Plug Gauge (Carbide Go) 26.020-26.041 procured as contingency of Air Gauge Unit (if Air gauge unit is under calibration so far used PPG for 100% Inspection at Final Inspection Stage) | Mr. Gaurav Nikam | 05/09/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No Changed |
| 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) |
Due to there is no Red Bin Available at machine stage so Rejected parts get mixed up 231_Occurance_Before.xlsx |
| Occurance (After) |
Now we have kept Red bin with lock and key for rejection parts (Set up /rework parts) 231_Occurance_After.xlsx |
| Outflow (Before) |
As Air Gauge Unit is under calibration so that 100% inspection not done at final stage 231_Outflow_Before.xlsx |
| Outflow (After) |
Duble Ended Plain Plug Gauge (Carbide Go) 26.020-26.041 procured as contingency of Air Gauge Unit (if Air gauge unit is under calibration so far used PPG for 100% Inspection at Final Inspection Stage) 231_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | |
| Specify Other Document | No Any Other Documen |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |