QFR No - 8000808535
Defect Details
| NC No. | 8000808535 |
| NC Date | 19/10/2022 |
| NC Submission Date | |
| Part No. | 550LG06202 |
| Part Name | SEAT PIPE -K23A/PRFH-006 |
| Supplier Name & Code | 100929-HARSHAD ENGINEERING COMPANY |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | DIMN.O/SIZE.-GROOVE WIDTH OVERSIZE |
1. Problem Description
| Defect Description | In PRFH Seat pipe - Groove width observed oversize. (No-go gauge qualifies.) |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 1021 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qaharshad@miteshauto.com |
| Plant Head/CEO Email ID | sjkadam@miteshauto.com |
| MD Email ID | auto.mitesh@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
6400
|
5800
|
0
|
8800
|
9600
|
30600
|
| Check Qty |
6400
|
5800
|
0
|
8800
|
9600
|
30600
|
| NG Qty |
1011
|
59
|
0
|
117
|
21
|
1208
|
| Scrap | 0 |
| Rework | 0 |
| Under Deviation | 1208 |
| Containment Action |
|---|
| 100 % sorting done for ETL End, HEC WIP & FG material |
3. Process Flow
| Process Flow Description |
|---|
| Cutting-Draw-Forging(Head Formation)-Rough Grinding-CNC (Head, Boring & Tapping)-Punching-Finish Grinding-Final Inspection-Packing-Dispatch |
4. Process Details
| Process / Operation | CNC Head Turning |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | CNC 1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | In CNC Prograam Groove width set to higher side | In CNC Prograam Groove width observed higher side at the time of insert change | 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 | IS2500 |
7. Root Cause Analysis (Occurance)
| Why 1 | Groove width found oversize |
| Why 2 | At the time of insert change, 80 to 90 nos found light NOGO enters due to entry chamfer. |
| Why 3 | In CNC programm groove width set to higher side. |
| Why 4 | To avoid Gr. Width undersize fitment issue. |
| Why 5 | To avoid Gr. Width undersize fitment issue. (entry chamfer minor excess observed in said lot) |
| Root Cause (Occurance) | To avoid Gr. Width undersize fitment issue. (entry chamfer minor excess observed in said lot) |
Root Cause Analysis (Outflow)
| Why 1 | Groove width found oversize |
| Why 2 | Part skip in FI |
| Why 3 | 100% check not done |
| Why 4 | Sampling done/Inspection method not adequete |
| Why 5 | |
| Root Cause (Outflow) | Sampling done/Inspection method not adequete |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | In CNC programe correction done and width size maintained at mean side and radius at entry point corrected to prevent the over size concern. | D.D. Jopale | 19/10/2022 | Completed | |
| Outflow | Groove width 100% check just before packing to avoid NG part mix-up in lot. | Vaibhav Shirsath | 18/10/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Groove width 100% check |
| 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) |
In CNC Program Groove width maintain at higher side 286_Occurance_Before.jpg |
| Occurance (After) |
In CNC Program Groove width maintain at Mean 286_Occurance_After.jpg |
| Outflow (Before) |
Groove width checked on Sampling basis 286_Outflow_Before.jpg |
| Outflow (After) |
100% insp. to be done for Groove width 286_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | CNC Machines |
12. Document Review
| Documents | |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Effectiveness observed. |