QFR No - 8000818063
Defect Details
| NC No. | 8000818063 |
| NC Date | 23/01/2023 |
| NC Submission Date | |
| Part No. | F20508007B |
| Part Name | UND BKT SUB-ASSEMBLY (K17B/D) |
| Supplier Name & Code | 100061-BAJAJSONS LIMITED |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-BALL RACE OD FOUND UNDERSIZE |
1. Problem Description
| Defect Description | Ball race OD found undersize |
| Detection Stage | Inprocess |
| Problem Severity | Safety |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | kasingh@bajajsons.com |
| Plant Head/CEO Email ID | crbansal@bajajsons.com |
| MD Email ID | sanjay.bajaj@bajajsons.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
600
|
1200
|
300
|
200
|
200
|
2500
|
| Check Qty |
600
|
600
|
0
|
200
|
200
|
1600
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All customer end , warehouse, transit & FG stock will re-check for this issue before dispatch to customer. |
3. Process Flow
| Process Flow Description |
|---|
| Pipe cutting-ID Deburring-Flaring-ID. Boring for bush fitting- Bush fitting-Bush welding- Length sizing & countering -CNC Turning-Thread rolling-Grinding 1st- Grinding 2nd- To Assy. |
4. Process Details
| Process / Operation | Grinding |
| Outsource | No |
| Machine / Cell | Centerless Grinding machine |
| Machine / Cell No. | CGM-01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Improper handling of setting part at Grinding machine | During verification found that setting part did not identify after setting,resulting part mixed up w | X |
| Tool | Chips stuck on control wheel | During verification found that control wheel dressing done freq. | O |
| Man | Unskilled manpower | During verification found that skilled manpower deployed | O |
| Method | Improper handling of NG part | During verification found that NG part did not identify | X |
| Material | Material hardness less | MTC verified & found ok | O |
| Machine | machine Spindle jam | During verification found that machine is ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Setting part mix up |
| Why 2 | Setting part mix up due to setting part kept at wrong place |
| Why 3 | Setting part kept at wrong place due to neglegency of operator |
| Why 4 | Neglegency of operator due to lack of awareness |
| Why 5 | |
| Root Cause (Occurance) | Neglegency of operator due to lack of awareness |
Root Cause Analysis (Outflow)
| Why 1 | NG part skipped from inspection stage |
| Why 2 | OK part mix up in NG part |
| Why 3 | Mix up due to no identified of NG part |
| Why 4 | NG part did not identify due to neglegency of checker |
| Why 5 | |
| Root Cause (Outflow) | NG part did not identify due to neglegency of checker |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Awareness given to machine operator for proper handling of NG part. A special lock type provision will be implement for setting part handling | Vijay Singh | 04/02/2023 | 31/01/2023 | Completed |
| Outflow | Awareness given to checker for proper identification of NG part & after identification NG part should be kept in lock & key provision | Sandeep | 31/01/2023 | 30/01/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | NG part will identify & after that part will kept in lock & key provision |
| 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) |
NG Part kept at wrong place 346_Occurance_Before.jpg |
| Occurance (After) |
NG Part kept at defined place 346_Occurance_After.jpg |
| Outflow (Before) |
NG part kept without identification 346_Outflow_Before.jpg |
| Outflow (After) |
NG Part identified ang kept in lock & key 346_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Other grinding machines |
12. Document Review
| Documents | PFMEA |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | Verified next 3 lot and found ok |