QFR No - 8000813650
Defect Details
| NC No. | 8000813650 |
| NC Date | 09/12/2022 |
| NC Submission Date | |
| Part No. | F2DZ09002B |
| Part Name | FORK BOLT -K17E |
| Supplier Name & Code | 100189-SANGKAJ STEEL PVT LTD. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-M6 NO-GO PASS |
1. Problem Description
| Defect Description | M6 No-Go pass in fork bolt |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 330 |
| 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 |
1000
|
0
|
0
|
1000
|
1000
|
3000
|
| Check Qty |
330
|
0
|
0
|
1000
|
1000
|
2330
|
| NG Qty |
30
|
0
|
0
|
0
|
0
|
30
|
| Scrap | 30 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Lot booked after found 30 nos NG at inward end, also re-verified the in-house stock. |
3. Process Flow
| Process Flow Description |
|---|
| Inward Inspection > Forging blank > CNC 1ST > CNC 2nd > Drilling > Tapping > Rolling > Plating > Final Inspection |
4. Process Details
| Process / Operation | Drilling |
| Outsource | No |
| Machine / Cell | Tapping |
| Machine / Cell No. | 2 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Collet Wear out | Drill fitment issue | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Sampling basis (DVC) |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10 OUT 100 |
7. Root Cause Analysis (Occurance)
| Why 1 | Drill ID O/S |
| Why 2 | Drill Overhanging |
| Why 3 | Play in collet |
| Why 4 | Collet wear out |
| Why 5 | |
| Root Cause (Occurance) | Collet wear out found |
Root Cause Analysis (Outflow)
| Why 1 | NG Piece not traced in sampling basis |
| Why 2 | sampling frequency found not effective |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | sampling frequency at FID found not effective (10%) |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Collet replaced with new one having close clamping having facility of clamp more area of drill bit. so that overhanging possibility get eliminate | Mr. Raut Sir | 12/12/2022 | 10/12/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Checking frequency increased to 100 % |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Collet Wear Out drill bit overhanging due to clamping area less. 318_Occurance_Before.pptx |
| Occurance (After) |
Collet replaced with new one having close clamping having facility of clamp more area of drill bit. so that overhanging possibility get eliminate. 318_Occurance_After.pptx |
| Outflow (Before) |
sampling frequency at FID found not effective (10%) 318_Outflow_Before.jpeg |
| Outflow (After) |
100 % Inspection Lot 318_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Drilling Machine 1 & 2 |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | FID Checksheet |
13. Effectiveness Of Action
| Reviewed Quantity | 300 |
| Reason for submission | Next 3 lot checked and found ok |