QFR No - 8000808154
Defect Details
| NC No. | 8000808154 |
| NC Date | 17/10/2022 |
| NC Submission Date | |
| Part No. | 550FA17433 |
| Part Name | FORK PIPE MACHINED |
| Supplier Name & Code | 100503-DIVYA INDUSTRIES |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-THREADING,CLUCKING,LENGTH NOTOK |
1. Problem Description
| Defect Description | Dimensional NG concern:- During assembly operation fitment parameters, like threading, caulking ID, total length observed not ok. |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 114 |
| 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 |
2600
|
0
|
0
|
0
|
0
|
2600
|
| Check Qty |
2600
|
0
|
0
|
0
|
0
|
2600
|
| NG Qty |
114
|
0
|
0
|
0
|
0
|
114
|
| Scrap | 10 |
| Rework | 104 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material Segregation at Customer End |
3. Process Flow
| Process Flow Description |
|---|
| 1)RM pipe Cutting Inward- 2)Store- 3)CNC 1st Caulking Side Machining -4)CNC 2nd side Machining -5) F1.5mm Drilling --6) Final Inspection -7) Packing -Dispatch |
4. Process Details
| Process / Operation | 3)CNC 1st Caulking Side Machining |
| Outsource | No |
| Machine / Cell | Fork Pipe CNC machine Shop. |
| Machine / Cell No. | CNC-5 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Fork Pipe face Unclean / Depth Under Size By0.2 -0.5 | Length Under Size by 0.2-0.5 of Fork Pipe Raw Material | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | .......... |
7. Root Cause Analysis (Occurance)
| Why 1 | Caulking Depth Under size |
| Why 2 | Caulking Side Face Unclean |
| Why 3 | CNC-1st Side - Caulking Side Facing Not Proper as Require Length |
| Why 4 | Raw Material Length Short |
| Why 5 | |
| Root Cause (Occurance) | Raw Material Length Short |
Root Cause Analysis (Outflow)
| Why 1 | Caulking Depth Under size |
| Why 2 | Face Unclean Defect Not Detect During Final Inspection |
| Why 3 | Inspector Not Aware Of Face Unclean |
| Why 4 | New Inspector |
| Why 5 | |
| Root Cause (Outflow) | Inspector Not Aware Of Face Unclean |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 1)Raw material Length Short. 2)New Final Inspector. | Mr Gadekar And Mr. Suresh Kapgate | 20/10/2022 | 20/10/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 1) Defected Samples display at Final Inspection And Machine .2) OJT to Machine Operator & New Inspector. |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | ... |
10. Evidance of Countermeasure
| Occurance (Before) |
Caulking Side face Unclean / Caulking side Depth Under Size 289_Occurance_Before.jpeg |
| Occurance (After) |
One Point Lesson Display / OJT to operators 289_Occurance_After.xlsx |
| Outflow (Before) |
Raw Material Length Short form Source Area 289_Outflow_Before.jpeg |
| Outflow (After) |
Ram material Inspection start 289_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Types Fork Pipe |
12. Document Review
| Documents | ControlPlan, PFMEA, InspCheckSheet |
| Specify Other Document | Raw material Inward |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |