QFR No - 8000807222
Defect Details
| NC No. | 8000807222 |
| NC Date | 08/10/2022 |
| NC Submission Date | |
| Part No. | 550DZ05202 |
| Part Name | FORK BOLT :PRFH-006 |
| Supplier Name & Code | 100189-SANGKAJ STEEL PVT LTD. |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | DIMN.O/SIZE.-DIM 3.2 OVERSIZE |
1. Problem Description
| Defect Description | Groove width oversize concern observed. After allowing segregation 620 nos. observed not OK. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 620 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualityassurance@sangkaj.com |
| Plant Head/CEO Email ID | steel@sangkaj.com |
| MD Email ID | anirudh.2007@hotmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5000
|
0
|
0
|
1000
|
1500
|
7500
|
| Check Qty |
5000
|
0
|
0
|
1000
|
1500
|
7500
|
| NG Qty |
620
|
0
|
0
|
0
|
0
|
620
|
| Scrap | 620 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Suspected qty verified at customer end and In-house. |
3. Process Flow
| Process Flow Description |
|---|
| Inward Inspection > Cold Draw > Straightning > Traube > Deburring > Grinding > CNC Turn > Tapping > Thread Rolling > Plating > Final Inspection |
4. Process Details
| Process / Operation | CNC |
| Outsource | No |
| Machine / Cell | CNC cell |
| Machine / Cell No. | 25 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Vibrations in tool Holder | Tool holder found loose | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5% |
7. Root Cause Analysis (Occurance)
| Why 1 | Groove Dimension o/s |
| Why 2 | Insert viable while machining |
| Why 3 | Insert not tighten properly |
| Why 4 | Insert holder pocket found wear out |
| Why 5 | |
| Root Cause (Occurance) | Insert holder pocket found wear out |
Root Cause Analysis (Outflow)
| Why 1 | NG Piece not traced in sampling basis |
| Why 2 | sampling frequency found less |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | sampling frequency at FID found less |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Tool holder chnaged | Mr. Raut Sir | 10/10/2022 | Pending |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Sampling frequency increased to 10 % |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10% |
10. Evidance of Countermeasure
| Occurance (Before) |
Insert holder pocket found wear out 278_Occurance_Before.pptx |
| Occurance (After) |
Tool holder chnaged 278_Occurance_After.pptx |
| Outflow (Before) |
sampling frequency at FID found less 278_Outflow_Before.jpeg |
| Outflow (After) |
Sampling frequency increased to 10 % 278_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | CNC |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | FID Checksheet |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |