QFR No - 8000820869
Defect Details
| NC No. | 8000820869 |
| NC Date | 20/02/2023 |
| NC Submission Date | |
| Part No. | F2FA08833M |
| Part Name | FORK PIPE MACHINED (K-9207) |
| Supplier Name & Code | 101030-TUBE INVESTMENTS OF INDIA LTD |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | TAPPING O/SIZE.-THREADING NOT OK |
1. Problem Description
| Defect Description | Threading Not Ok |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 4 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | AmitVD@tii.murugappa.com |
| Plant Head/CEO Email ID | guptaajay@tii.murugappa.com |
| MD Email ID | mukeshahuja@tii.murugappa.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1300
|
0
|
0
|
400
|
0
|
1700
|
| Check Qty |
1300
|
0
|
0
|
400
|
0
|
1700
|
| NG Qty |
4
|
0
|
0
|
0
|
0
|
4
|
| Scrap | 4 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1) All K-9207 TFF Model Stock checked at ETL K-228 WIP & SM sales Inhouse FG for Trending Not OK Concern. 2)Total NG Part Qty: 4 Nos. at ETL K-228 end. 3) 100 % WIP Material checked at TPI Aurangabad M/C Center (SM Sales) Also Blue Marker marking done as A Identification for Inspection & No NG Part Observed at TPI Aurangabad M/C Center (SM Sales) |
3. Process Flow
| Process Flow Description |
|---|
| Incoming Material - Inward Inspection - Storage - CNC Machining Threading Side - CNC Machining Caulking Side - Drilling - Deburring - Final Inspection - Packing in Bins - Dispatch to ETL. |
4. Process Details
| Process / Operation | CNC Machining Threading Side |
| Outsource | No |
| Machine / Cell | CNC Machining Cell |
| Machine / Cell No. | CNC N0.10 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Threading Major Dia Undersize | Verified through Gemba observation Threading Insert found wear before decided frequency | X |
| Method | Inspection SOP not Followed | Verified through Gemba visit found Inspection for Threading done by using TPG on sampling Basis | O |
| Man | Unskilled Operator | Verified found Skilled Operator | 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 | 2 Nos./Hrs |
7. Root Cause Analysis (Occurance)
| Why 1 | Threading Not OK |
| Why 2 | Major Dia observed Undersize |
| Why 3 | Threading Insert observed wear out before defined Insert change frequency. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Threading Insert observed wear out before defined Insert change frequency. |
Root Cause Analysis (Outflow)
| Why 1 | Threading Not OK |
| Why 2 | Not detected during the Inspection by using Thread plug gauge |
| Why 3 | Not Detected as the Inspection on Sampling basis 2 Nos./Hrs |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Not Detected as the Inspection on Sampling basis 2 Nos./Hrs |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | After Discussion with Production Incharge of machining Cell, Threding Insert change frequency changed from 450 Nos. per Corner to 350 Nos. per Corner | Mr. Rathod | 23/02/2023 | 23/02/2023 | Completed |
| Outflow | Sampling Inspection Qty. increased during hourly inspection by 2 Nos./Hrs to 5 Nos. | Mr. Sandip Johare | 23/02/2023 | 23/02/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % Inspection for Threading by using Thread plug gauge & Blue Marker marking done as A Identification for next 3 lot |
| 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) |
1) Threading Insert observed wear out before defined Insert change frequency. 2)Threading Insert change frequency was 450 Nos. per Corner. 376_Occurance_Before.pdf |
| Occurance (After) |
Threading Insert change frequency has been changed from 450 Nos. per Corner to 350 Nos. per Corner 376_Occurance_After.pdf |
| Outflow (Before) |
Not Detected as the Inspection on Sampling basis 2 Nos./Hrs 376_Outflow_Before.pdf |
| Outflow (After) |
Sampling Inspection Qty. increased during the hourly inspection by 2 Nos./Hrs to 5 Nos. 376_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All M/c`s at CNC Machining Cell |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | Tool History Card |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | Ok |