QFR No - 8000814130
Defect Details
| NC No. | 8000814130 |
| NC Date | 14/12/2022 |
| NC Submission Date | |
| Part No. | 550PC09107 |
| Part Name | UNDER BKT M/C (CT100) |
| Supplier Name & Code | 101222-SANGKAJ ENGINEERING PVT LTD- U |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-STEERING SHAFT SITTING ID UNDERSIZE |
1. Problem Description
| Defect Description | Under bracket, steering shaft inserting id found undersize |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 643 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | samadhan@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 |
800
|
0
|
0
|
200
|
0
|
1000
|
| Check Qty |
800
|
0
|
0
|
200
|
0
|
1000
|
| NG Qty |
643
|
0
|
0
|
0
|
0
|
643
|
| Scrap | 0 |
| Rework | 643 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% inspection of Pipe line material. |
3. Process Flow
| Process Flow Description |
|---|
| Forging inward --- Pre-drilling ---- VMC 1St setup ---- VMC 2nd setup ---- VMC 3rd Setup ---- VMC 4th setup ----Final Inspection |
4. Process Details
| Process / Operation | VMC 1st Setup |
| Outsource | No |
| Machine / Cell | VMC machine |
| Machine / Cell No. | Cell no. 4 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Tool Worn Out | Tool life monitoring not done | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | Centre Bore ID Undersize |
| Why 2 | Premature Failure Of Insert (Tool) |
| Why 3 | Insert (Tool) Get Wear Out |
| Why 4 | Insert (Tool) life not Monitoring |
| Why 5 | Insert (Tool) life Not Define. |
| Root Cause (Occurance) | Insert (Tool) life Not Define. |
Root Cause Analysis (Outflow)
| Why 1 | Centre Bore ID Undersize |
| Why 2 | Not Capture in Final Inspection |
| Why 3 | 0.010 mm Dial Bore Gauge used for Final Inspection |
| Why 4 | No Air gauge Used For Final Inspection |
| Why 5 | No Air gauge Used For Final Inspection |
| Root Cause (Outflow) | No Air gauge Used For Final Inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Insert (Tool) life Not Define. | Mr.Dhage | 28/12/2022 | 29/12/2022 | Completed |
| Outflow | No Air gauge Used For Final Inspection | Mr.Pramod Waikos | 15/01/2023 | 18/01/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Air Plug Gauge is used for ID inspection. |
| 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) |
Photo Not Available 321_Occurance_Before.png |
| Occurance (After) |
Tool life format 321_Occurance_After.jpeg |
| Outflow (Before) |
Bore Gauge is used to inspect the part. 321_Outflow_Before.png |
| Outflow (After) |
Air gauge is used to inspect the part. 321_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | CT100, Caliber |
12. Document Review
| Documents | ControlPlan, WISOP |
| Specify Other Document | Work Instruction |
13. Effectiveness Of Action
| Reviewed Quantity | 300 |
| Reason for submission | Verified and found ok next lot |