QFR No - 8000820612
Defect Details
| NC No. | 8000820612 |
| NC Date | 15/02/2023 |
| NC Submission Date | |
| Part No. | S3HT00307B |
| Part Name | OUTER SPRING POWDER COATED-TVS KING RR |
| Supplier Name & Code | 101225-HELICAL SPRINGS |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | LENGTH OVERSIZE-LENGTH OVERSIZE |
1. Problem Description
| Defect Description | Total length oversize concern observed. Length oversize by 2 to 3 mm. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 295 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | ravindra@helicalsprings.in |
| Plant Head/CEO Email ID | shaikhmoin@helicalsprings.in |
| MD Email ID | ataneja@helicalsprings.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
410
|
0
|
0
|
0
|
300
|
710
|
| Check Qty |
410
|
0
|
0
|
0
|
300
|
710
|
| NG Qty |
295
|
0
|
0
|
0
|
300
|
595
|
| Scrap | 0 |
| Rework | 295 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All pipeline material at ETL & Helical end checked for length over size defect.Ok material given for next stage. |
3. Process Flow
| Process Flow Description |
|---|
| Raw Material Receipt & Inspection> Coiling > Stress Relieving > End Grinding > Shot Peening > Scragging > ID, Length & Angle checking > Surface Finish- Powder Coating > Final Inspection> Packing > Dispatch |
4. Process Details
| Process / Operation | ID & Length checking |
| Outsource | No |
| Machine / Cell | Spring Line |
| Machine / Cell No. | N/A |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | No Manpower Change | Data Verified | O |
| Tool | No Tooling Change | Tooling Sheet Checked Found Ok | O |
| Method | Reworked Material Mix In Ok Material | Only One Yellow Bin Used. | X |
| Material | No Material Change | Data Checked Found Ok | O |
| Machine | No Machine Change | No Machine Change | 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 | Length Oversize Observed At Customer End. |
| Why 2 | Length Oversize Sampling Mix With Ok Lot. |
| Why 3 | Length Oversize Material Kept in Green Bin |
| Why 4 | Yellow Bin At Use Was Only 1 |
| Why 5 | No Extra Yellow Bin Used By Operator For More Qty Of RW |
| Root Cause (Occurance) | No Extra Yellow Bin Used By Operator For More Qty Of RW |
Root Cause Analysis (Outflow)
| Why 1 | Length Oversize Observed At Customer End. |
| Why 2 | Mix Up Of RW Samples Occurred After 100% Sampling. |
| Why 3 | - |
| Why 4 | - |
| Why 5 | - |
| Root Cause (Outflow) | Mix Up Of RW Samples Occurred After 100% Sampling. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | OPL Displayed For Usage Of Yellow Bins only For RW. Training Provided. | Prod. | 28/02/2023 | 28/02/2023 | Completed |
| Occurance | OPL Displayed For Usage Of Yellow Bins Only For RW. | Prod. | 28/02/2023 | 28/02/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No Changes in Inspection System |
| 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) |
Operator Used Green Bins To Keep Extra RW Material 363_Occurance_Before.pdf |
| Occurance (After) |
OPL Displayed For Using Only Yellow Bins For RW Material. 363_Occurance_After.pdf |
| Outflow (Before) |
Operator Used Green Bins To Keep Extra RW Material 363_Outflow_Before.pdf |
| Outflow (After) |
Training Provided To Operators. 363_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Items |
12. Document Review
| Documents | WISOP, ProcessFlowChart |
| Specify Other Document | OPL & Training Sheet |
13. Effectiveness Of Action
| Reviewed Quantity | 10 |
| Reason for submission | Corrective action parts submission. |