QFR No - 8000817072
Defect Details
| NC No. | 8000817072 |
| NC Date | 13/01/2023 |
| NC Submission Date | |
| Part No. | 520LG03002 |
| Part Name | SEAT PIPE (K3) |
| Supplier Name & Code | 101263-SINGLA PRECISION SCREWS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-BURR BACK SIDE OF DF HOLE (INNER SIDE) |
1. Problem Description
| Defect Description | Burr found inside the seat pipe ID (Back side of the DF Hole), causing fitment issue during assembly |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 75 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@singlaprecision.com |
| Plant Head/CEO Email ID | quality@singlaprecision.com |
| MD Email ID | aditya@singlaprecision.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1200
|
600
|
0
|
0
|
0
|
1800
|
| Check Qty |
1200
|
600
|
0
|
0
|
0
|
1800
|
| NG Qty |
75
|
2
|
0
|
0
|
0
|
77
|
| Scrap | 75 |
| Rework | 2 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % SEGRATION DONE ON MATERIAL LYING AT VARIOUS STAGES AND MARKING TOBE DONE. |
3. Process Flow
| Process Flow Description |
|---|
| 1.R.M INSPECTION 2.HEAD FORGING 3.PUNCHING-1 4.ROUGH GRINDING 5.CNC-1 6.CNC-2 7.COUNTER 8.PUNCHING-II 9. I.D CHIPS REMOVE 10.REAMING (IF NECESSARY) 11.TAPPING 12. FINAL GRINDING 13.CLEANING 14.FINAL INSPECTION 15.PACKING |
4. Process Details
| Process / Operation | I.D BURR REMOVING |
| Outsource | No |
| Machine / Cell | DRILL |
| Machine / Cell No. | DRILL05 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | UNSKILLED OPERATOR | VALIDATED AND FOUND OK | X |
| Tool | DRILL MAY WEAR | VALIDATED AND FOUND OK | X |
| Material | RM GRADE NOT OK | VALIDATED AND FOUND OK | X |
| Machine | NUT BOLTS MAY LOOSE | VALIDATED AND FOUND OK | X |
| Method | BURR MAY FOLD IN I.D | Burr formed during punching operation and stuck in I.D and not visible. It comes out during filing | 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 | 5 PCS/HOUR |
7. Root Cause Analysis (Occurance)
| Why 1 | Heavy burr found back side of the DF hole. |
| Why 2 | Burr formed during punching operation |
| Why 3 | It stuck in I.D and not visible |
| Why 4 | It comes out during filing and pin operation and rise in I.D |
| Why 5 | |
| Root Cause (Occurance) | Burr formed during punching operation and stuck in I.D and not visible. It comes out during filing and pin operation and rise in I.D. |
Root Cause Analysis (Outflow)
| Why 1 | Inspection plan was not effective. |
| Why 2 | NG part skipped from detection |
| Why 3 | So NG part dispatched to customer |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspection plan was not effective. NG part skipped from detection .So NG part dispatched to customer |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Inspection frequency changed to 100% at final inspection | Ganesh Maurya | 19/01/2023 | 19/01/2023 | Completed |
| Occurance | 1- WORK INSTRUCTIONS GIVEN TO OPERATOR AND INSPECTOR REGARDING THE DEFECT OF BURR IN I.D 2. WE STARTED 100% DIA 15.10 mm PIN APPLIED IN I.D TO REMOVE THE BURR. | Ganesh Maurya | 19/01/2023 | 19/01/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | WE STARTED 100% DIA 18.10 mm PIN APPLIED IN I.D TO REMOVE THE BURR. |
| 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) |
NO PIN APPLICATION 329_Occurance_Before.jpeg |
| Occurance (After) |
PIN APPLIED 329_Occurance_After.jpeg |
| Outflow (Before) |
INSPECTION WAS ACC TO SAMPLING 329_Outflow_Before.jpeg |
| Outflow (After) |
SAMPLING PLAN CHANGED TO 100% 329_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All seat pipes |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | Ensure 100% inspection with insert pin as per commitment |