QFR No - 8000804510
Defect Details
| NC No. | 8000804510 |
| NC Date | 16/09/2022 |
| NC Submission Date | |
| Part No. | 520PB00102 |
| Part Name | RAW TUBE FOR LH EXTENSION |
| Supplier Name & Code | 101109-TUBE INVESTMENTS OF INDIA LIMI |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | DEEP MARK-INSIDE LINE MARK |
1. Problem Description
| Defect Description | Deep Line Marks in ID |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 8 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | zmbv35ocemqkce1uvbnl5riy.jpg |
Supplier Communication Details
| Quality Head Email ID | anandms@tii.murugappa.com |
| Plant Head/CEO Email ID | BhatnagarS@tii.murugappa.com |
| MD Email ID | mukeshahuja@tii.murugappa.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2100
|
0
|
0
|
1000
|
400
|
3500
|
| Check Qty |
2100
|
0
|
0
|
1000
|
400
|
3500
|
| NG Qty |
8
|
0
|
0
|
0
|
0
|
8
|
| Scrap | 8 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1. All available CL tubes segregation done at both ETL & TI Sanand WH and identified with blue marker inside tube ID. 2. All available Long Length tubes segregation done at TI Sanand WH and identified with blue marker inside tube ID. 3. No stock available at plant in Long length. |
3. Process Flow
| Process Flow Description |
|---|
| Plant Process Flow :- Slitting - Tube rolling - Annealing - Wet Process - Push Pointing/Swaging - Final drawing - Straightening - Cutting - ECT - Inspection - Packing - Dispatch to TI Sanand WH. Sanand WH Process Flow :- Inward Inspection - Storage - Cutting - Deburring - Cleaning - Inspection - Packing in Bins - Dispatch to ETL Sanand. |
4. Process Details
| Process / Operation | Wet process & Tube drawing |
| Outsource | No |
| Machine / Cell | Draw Bench |
| Machine / Cell No. | 40T Draw Bench |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Operator Skill | Verified through Gemba observation and found Operator Skill as per Matrix | O |
| Material | Hollow ID mark tube | Verified through Simulation and found that ID mark generated | O |
| Material | Hollow tube ID wet | Verified through Simulation & found the (ID Scoring mark ) defective part generated for this cause. | X |
| Tool | Plug damage | Verified through Simulation and found that ID mark/scoring mark generated | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual. (By finger) |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 Nos |
7. Root Cause Analysis (Occurance)
| Why 1 | ID score mark tubes found at Customer ETL end in Cut Length. |
| Why 2 | Plug pick up mark in drawing. |
| Why 3 | Inside diameter of the tube wet |
| Why 4 | Sucker side Dryer fan not working. |
| Why 5 | Plug got pick up mark due to Wet ID. |
| Root Cause (Occurance) | Hollow tube ID wet |
Root Cause Analysis (Outflow)
| Why 1 | ID score mark tubes found at Customer ETL end in Cut Length. |
| Why 2 | Not detected during final inspection. |
| Why 3 | Inspection done as per sampling plan Ref. IS 4711 - 1974 |
| Why 4 | By system design |
| Why 5 | |
| Root Cause (Outflow) | Inspection was done on sampling basis. (IS 4711 - 1974) |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Sucker side dryer fan rectified | Mr. Jadhav | 22/08/2022 | 21/08/2022 | Completed |
| Outflow | 1. 100 % Inspection will be done at both ends of the tube. (Next three Lots) 2. Sampling qty will be doubled during final inspection. (IS 4711 - 1974) | Mr. Sangmesh | 23/09/2022 | 20/09/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 1.100 % Inspection will be done at both ends of the tube. (Next three Lots) 2. Sampling qty doubled during final inspection. (IS 4711 - 1974) 3. On draw bench during first off , 2nos & hourly Visual. (By finger) |
| Inspection Method | Other |
| Other Inspection Method | Visual (By finger) |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Left side sucker Fan was not working. 253_Occurance_Before.pptx |
| Occurance (After) |
Sucker side dryer fan rectified. 253_Occurance_After.pptx |
| Outflow (Before) |
Inspection was done on sampling basis.
(IS 4711 - 1974) 253_Outflow_Before.pptx |
| Outflow (After) |
1. 100 % Inspection will be done at both ends of the tube. (Next three Lots) 2. Sampling qty will be doubled during final inspection. (IS 4711 - 1974) 253_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applicable for all CDW tubes. |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 1134 |
| Reason for submission | VERFIED 1134 NOS. RAW TUBE PART FOUND OK. VERIFICATION WAS MADE FOR 5 LOTS 100%. |