QFR No - 8000814841
Defect Details
| NC No. | 8000814841 |
| NC Date | 20/12/2022 |
| NC Submission Date | |
| Part No. | F2FA21433M |
| Part Name | FORK PIPE MACHINED (K17A FF) |
| Supplier Name & Code | 101024-TUBE INVESTMENTS OF INDIA LTD |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | DEPTH U/SIZE.-CAULKING DEPTH UNDER SIZE |
1. Problem Description
| Defect Description | Caulking depth under size in fork pipe K17 |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 235 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | AmitVD@tii.murugappa.com |
| Plant Head/CEO Email ID | guptaajay@tii.murugappa.com |
| MD Email ID | mukeshahuja@tii.murugappa.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2500
|
2000
|
0
|
0
|
0
|
4500
|
| Check Qty |
2500
|
2000
|
0
|
0
|
0
|
4500
|
| NG Qty |
235
|
5
|
0
|
0
|
0
|
240
|
| Scrap | 240 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% segregation done at customer end & 100% segregation done at warehouse |
3. Process Flow
| Process Flow Description |
|---|
| 1. Parting 2. CNC Machining First 3. CNC Machining 2nd 4. Drilling |
4. Process Details
| Process / Operation | Machining & Drilling |
| Outsource | No |
| Machine / Cell | MACHINE SHOP |
| Machine / Cell No. | CNC MACHINE -01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Inspection Instruments & Lux Level | Inspection with DPG, Lux level- 620 | O |
| Man | Operator | Untrained operator given Wrong offset in Programme | X |
| Material | Tube Id & Machining Margin | As per Specs. | O |
| Tool | Temperature & Humidity | No Issue | O |
| Machine | CNC Programme execution | Programme not Locked | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | Fork Pipe Caulking Depth Undersize |
| Why 2 | Depth Less maintained during CNC Machining |
| Why 3 | Due to wrong offset given in the Programme by operator |
| Why 4 | Programme was not Locked |
| Why 5 | |
| Root Cause (Occurance) | Operator was Untrained and CNC programme was not Locked, Due to Which wrong offset given in Programme by the Operator. |
Root Cause Analysis (Outflow)
| Why 1 | Fork Pipe Caulking Depth Undersize Part received at Customer end |
| Why 2 | Caulking Depth Inspection done on sampling basis. |
| Why 3 | 100% Inspection not defined in the WI |
| Why 4 | Because This type of defect not reported in past |
| Why 5 | |
| Root Cause (Outflow) | This Parameter was checking on Sampling basis, because This type of defect not reported in past. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1. CNC Programme Locked 2. Only Production Supervisor will give the offset. 3. After any correction Quality Line Inspector will recheck the parts and provide approval. | TANVEER | 16/12/2022 | 15/12/2022 | Completed |
| Outflow | 1. After every 50Parts, operator will check this parameter with Attribute Gauge. 2. 100% Inspection Started at PDI Stage. | TANVEER | 16/12/2022 | 15/12/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Inspection started at PDI Stage |
| 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) |
CNC Programme Not Locked 323_Occurance_Before.jpeg |
| Occurance (After) |
CNC Programme Locked 323_Occurance_After.jpeg |
| Outflow (Before) |
After every 50 Parts, operator will check this parameter with Attribute Gauge.ONLY BASIC TRAINING GIVEN 323_Outflow_Before.jpg |
| Outflow (After) |
100% Inspection Started at PDI Stage. 323_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Models |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | QUALITY ALERT |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | ok |