QFR No - 8000818250
Defect Details
| NC No. | 8000818250 |
| NC Date | 24/01/2023 |
| NC Submission Date | |
| Part No. | F2DZ04603B |
| Part Name | FORK BOLT J1A & J1D |
| Supplier Name & Code | 101263-SINGLA PRECISION SCREWS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-THREAD M38 GO GAUGE & MATING PART NOT QU |
1. Problem Description
| Defect Description | M38 Threading found damage marks and not qualifying to mating part |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1600 |
| 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 |
2000
|
0
|
0
|
0
|
0
|
2000
|
| Check Qty |
2000
|
0
|
0
|
0
|
0
|
2000
|
| NG Qty |
1600
|
0
|
0
|
0
|
0
|
1600
|
| Scrap | 0 |
| Rework | 1600 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% GAUGE INSPECTION DONE ON THE MATERIAL LYING AT VARIOUS STAGES |
3. Process Flow
| Process Flow Description |
|---|
| 1.RM 2. CUTTING 3. O.D CLG 4. DRILLING+FACING 5. TAPPING 6. RE-TAPPING CHECK 7. CNC TURNING 8. BACK FACE BUFFING+MILLING BURR REMOVE 10. FINAL INSPECTION 11. PACKING AND DISPATCH(ROHTAK TO WAREHOUSE AURANGABAD) 12. SURFACE TREATMENT 13.FINAL SORTING 14.PACKING AND DISPATCH ( WAREHOUSE TO ETL) |
4. Process Details
| Process / Operation | TRANSPORTATION (ROHTAK TO WAREHOUSE) |
| Outsource | No |
| Machine / Cell | TRANSPORTATION |
| Machine / Cell No. | TRANSPORTATION |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | RM SIZE AND GRADE NOT OK | VALIDATED AND FOUND OK | X |
| Machine | NUT BOLTS MAY LOOSE | VALIDATED AND FOUND OK | X |
| Method | INSPECTION METHOD NOT EFFECTIVE | VALIDATED AND FOUND OK | X |
| Man | MISHANDLING OF MATERIAL | DURING TRANSPORTATION THREAD OF PARTS WERE NOT PROPERLY COVERED AND THREAD GOT DAMAGE OF SOME PIECES | O |
| Tool | ROLLING DIE WEAR | VALIDATED AND FOUND OK | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | ACC. PLAN |
7. Root Cause Analysis (Occurance)
| Why 1 | M38 THREAD NOT OK |
| Why 2 | DURING TRANSPORTATION FROM ROHTAK TO WAREHOUSE THREAD GOT DAMAGE |
| Why 3 | THREAD WERE NOT COVERED DURING PACKING |
| Why 4 | SO THREAD GOT DAMAGE |
| Why 5 | |
| Root Cause (Occurance) | DURING TRANSPORTATION FROM ROHTAK TO WAREHOUSE THREAD GOT DAMAGE.THREAD WERE NOT COVERED DURING PACKING.SO THREAD GOT DAMAGE. |
Root Cause Analysis (Outflow)
| Why 1 | M38 THREAD NOT OK |
| Why 2 | TRANSPORT FACILITY WAS FIRST SHARED WITH OTHER COMPANIES. |
| Why 3 | DURING TRANSPORT HANDLING OF MATERIAL WAS NOT EFFECTIVE. |
| Why 4 | SO NG PARTS DISPATCHED TO CUSTOMER |
| Why 5 | |
| Root Cause (Outflow) | TRANSPORT FACILITY WAS FIRST SHARED WITH OTHER COMPANIES.DURING TRANSPORT HANDLING OF MATERIAL WAS NOT EFFECTIVE.SO NG PARTS DISPATCHED TO CUSTOMER. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | TRANSPORT FACILITY CHANGED.NOW OUR MATERIAL WILL BE DISPATCHED DIRECTLY FROM ROHTAK TO WAREHOUSE WITH SINGLE TRANSPORT TO AVOID THE MISHADLING OF MATERIAL. | GANESH MAURYA | 30/01/2023 | 31/01/2023 | Completed |
| Occurance | THREADS COVERED PROPERLY WITH CAP AND PROPER BOX USED FOR PACKING THE MATERIAL TO AVOID THE CONTACT OF MATERIAL WITH EACH OTHER TO PREVENT DENT AND DAMAGES. | GANESH MAURYA | 30/01/2023 | 31/01/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NO CHANGE |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | ACC.PLAN |
10. Evidance of Countermeasure
| Occurance (Before) |
THREADS WERE NOT COVERED PROPERLY 347_Occurance_Before.pdf |
| Occurance (After) |
THREADS COVERED WITH CAP PROPERLY 347_Occurance_After.pdf |
| Outflow (Before) |
TRANSPORT FACILITY WAS NOT EFFECTIVE 347_Outflow_Before.pdf |
| Outflow (After) |
TRANSPORT FACILITY CHANGED 347_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | ALL FORK BOLTS |
12. Document Review
| Documents | PackingStd |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 300 |
| Reason for submission | Checked next 3 lot and found ok |