QFR No - 8000821835
Defect Details
| NC No. | 8000821835 |
| NC Date | 25/02/2023 |
| NC Submission Date | |
| Part No. | 530MX00812 |
| Part Name | STEEL BUSH (FeZn8+ Bight Passivation) |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | DEEP MARK- ID UNCLEAN, ID LINE MARK . |
1. Problem Description
| Defect Description | INNER DIA. UNCLEAN SPARIAL MARKS & LINING MARK |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 200 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@apw3.co.in |
| Plant Head/CEO Email ID | kurund.ma@sharp-engineers.com |
| MD Email ID | urkhandelwal@sharp-engineers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5000
|
0
|
0
|
0
|
5000
|
10000
|
| Check Qty |
5000
|
0
|
0
|
0
|
5000
|
10000
|
| NG Qty |
200
|
0
|
0
|
0
|
50
|
250
|
| Scrap | 0 |
| Rework | 150 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done all the pipeline material and WIP. |
3. Process Flow
| Process Flow Description |
|---|
| 1) RM Inward inspection 2) 2 Storage 3) Parting and Chamfering 4) Chamfering 5) Plating (Out source) 6) Inward inspection 7) Final Inspection 8) Pre-Dispatch inspection 9) Packing & Dispatch |
4. Process Details
| Process / Operation | Purchasing |
| Outsource | Yes |
| Machine / Cell | NA |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Defective materi i.e. OD line mark/ID line mark/Length& dimensional variation. | Inward inspection as per SSPN IS:2500 | X |
| Man | Judgment error While checking | Master sample/ Limit sample provided for Checking at final as well as process stage | O |
| Machine | Inadequate check Point in JH check sheet | Monthly JH check sheet available on machine and all the check point is being checked and recorded as | O |
| Tool | Wrong Tool Insert selection | SOP/WI/CP available on machine and operator aware about it and being followed. | O |
| Method | Part inspection visually as per control plan and inspection check sheet | Part are being checked as per control plan and inspection check sheet and record updated. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
7. Root Cause Analysis (Occurance)
| Why 1 | Steel Bush ID line mark part reached at ETL |
| Why 2 | RM tube Ø18X12.10 ID line mark itself |
| Why 3 | RM defect |
| Why 4 | NO machining for inner diameter |
| Why 5 | By system design |
| Root Cause (Occurance) | NO machining for inner diameter |
Root Cause Analysis (Outflow)
| Why 1 | ID line mark part reached at ETL |
| Why 2 | Inadequate part/defect knowledge to operator/inspector. |
| Why 3 | New defect phenomena |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | OPL & Q alert not displayed on machine and final inspection stage and Inadequate part/defect knowledge to operator/inspector. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | OPL & Q alert displayed on machine and final inspection stage and training given to all concerns. | Mr. Shaikh Laik | 04/04/2023 | 04/04/2023 | Completed |
| Occurance | 100% inspection started after receipt of RM at machining stage, while loading the tube in the machine collet. | Mr. Datta Pandhre | 04/04/2023 | 04/04/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | OPL & Q alert displayed on machine and final inspection stage and training given to all concerns. |
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
Check point not added in the control plan at parting stage . 380_Occurance_Before.jpg |
| Occurance (After) |
100% inspection started after receipt of RM at machining stage while loading the tube in the machine collet. 380_Occurance_After.jpg |
| Outflow (Before) |
Check point not evident in CP. OPL & Q alert not displayed on machine and final inspection stage and Inadequate part/defect knowledge to operator/inspector. 380_Outflow_Before.jpg |
| Outflow (After) |
Control plan revised and check point added. OPL & Q alert displayed on machine and final inspection stage and training given to all concerns. 380_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | STEEL BUSH 312 & 412 |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | DEEP MARK- ID UNCLEAN, ID LINE MARK |