QFR No - 8000820733
Defect Details
| NC No. | 8000820733 |
| NC Date | 16/02/2023 |
| NC Submission Date | |
| Part No. | 520HL00202 |
| Part Name | OIL LOCK COLLAR |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-TOTAL LENGTH UNDERSIZE BY 0.20 MM |
1. Problem Description
| Defect Description | Oil lock collar total length found undersize by 0.20 mm |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 62 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@mahavirind.co.in |
| Plant Head/CEO Email ID | production@mahavirind.co.in |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1200
|
0
|
0
|
1840
|
0
|
3040
|
| Check Qty |
1200
|
0
|
0
|
1840
|
0
|
3040
|
| NG Qty |
62
|
0
|
0
|
1
|
0
|
63
|
| Scrap | 63 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Material Segregation at Customer End |
3. Process Flow
| Process Flow Description |
|---|
| RM Inward- store- Parting - Bottom Chamfer-Semi finish Inward- OD Grinding Process- Plating - Final Inspection- Dispatch - Transport. |
4. Process Details
| Process / Operation | Parting -ID Chamfer 2X15° |
| Outsource | Yes |
| Machine / Cell | Traub Section |
| Machine / Cell No. | Traub No.03 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Machine Part Stopper Not Proper working | Part stopper Brazing crack | 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 under size / over size |
| Why 2 | Resting Stopper Not Proper Working On Traub machine during parting process |
| Why 3 | Stopper Occurs Flexible During Raw material Pipe Resting on Stopper. |
| Why 4 | Resting Stoper Found Crack As per Attached Photograph. |
| Why 5 | |
| Root Cause (Occurance) | Stoper crack on traub machine during parting process.2 |
Root Cause Analysis (Outflow)
| Why 1 | Length under size / over size |
| Why 2 | Defective material not detect in sampling on final inspection stage During material dispatch |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Defective material not detect in sampling on final inspection stage During material dispatch |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Occurance- New stopper arrange on traub machine in place of old Crack stopper. Detection-New Gauge (OD AND LENGTH )Provide On Final Inspection Stage. | Mr. Pralhad Bhawar / Mr.Suresh Kapgate. | 26/03/2023 | 26/03/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | New Combine Gauge (OD And Length )Provide On Final Inspection Stage. and Separate Snap Gauge. |
| 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) |
Stopper Crack Point was Not Add in Daily PM Check sheet. 370_Occurance_Before.xlsx |
| Occurance (After) |
Daily PM Check sheet Stopper Crack Point Add. 370_Occurance_After.xlsx |
| Outflow (Before) |
Sampling Purpose Snap Gauge Use 370_Outflow_Before.xlsx |
| Outflow (After) |
100% OD and Length Purpose Combine gauge Use. 370_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Oil Lock Collar Models |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, PFMEA |
| Specify Other Document | OJT |
13. Effectiveness Of Action
| Reviewed Quantity | 300 |
| Reason for submission | Verified next 3 lot and found ok |