QFR No - 8000822306
Defect Details
| NC No. | 8000822306 |
| NC Date | 01/03/2023 |
| NC Submission Date | |
| Part No. | B2TD00626O |
| Part Name | ANCHOR PIN 9 MM DIA - REML |
| Supplier Name & Code | 100846-SANGKAJ ENGINEERING PVT.LTD. |
| ETL Plant | 1156-ETL Disc Brake P'Nagar |
| Defect Details | DIMN.U/SIZE.-OPERATION MISS |
1. Problem Description
| Defect Description | operation miss & wrong thread pieces received |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 22 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | aslam@sangkaj.com |
| Plant Head/CEO Email ID | pardeshinr@sangkaj.com |
| MD Email ID | anirudh.2007@hotmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5480
|
0
|
0
|
0
|
0
|
5480
|
| Check Qty |
4000
|
0
|
0
|
0
|
0
|
4000
|
| NG Qty |
22
|
0
|
0
|
0
|
0
|
22
|
| Scrap | 22 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done at ETL-Pantnagar End |
3. Process Flow
| Process Flow Description |
|---|
| Raw material inward-wire draw-cold forging-CNC machining-Rolling-Heat treatment-plating-final inspection-PDI-dispatch |
4. Process Details
| Process / Operation | Cold forging |
| Outsource | No |
| Machine / Cell | Cold forging |
| Machine / Cell No. | 19B4S |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Semi finished part fallen down in chute and got mix with OK parts at cold forging stage. | Cause verified. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Anchor pin 9mm, dimn U/S and operation missing found at ETL |
| Why 2 | Incomplete operation part found with ok parts |
| Why 3 | Part fallen down through 3rd station ,where 4th station is final station. |
| Why 4 | Part skipped through part shifting fingers. |
| Why 5 | Fingers worn out. |
| Root Cause (Occurance) | Part shifting fingers worn out. |
Root Cause Analysis (Outflow)
| Why 1 | Anchor pin 9mm, dimn U/S and operation missing found at ETL |
| Why 2 | NG parts got mixed with Ok parts at final inspection. |
| Why 3 | Final inspection is carried out visually. |
| Why 4 | At visual inspection more than one part holding in hand by inspector. |
| Why 5 | Part holding method while doing visual inspection is wrong. |
| Root Cause (Outflow) | Part holding method while doing visual inspection is wrong. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Work instruction reviewed and updated to ensure condition of fingers. | Mr. Shrikant Magar | 20/03/2023 | 16/03/2023 | Completed |
| Outflow | OPL displayed to ensure one part at a time should be hold. | Aslam Shaikh | 15/03/2023 | 15/03/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Part holding method has been changed , now only one part at a time is being hold while doing visual inspection. |
| Inspection Method | Other |
| Other Inspection Method | visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Assuring of condition of fingers of cold forging was not in process as not mentioned in WI for setup. 383_Occurance_Before.pdf |
| Occurance (After) |
WI updated and training also provided to assure condition of fingers of cold forging machine 383_Occurance_After.pdf |
| Outflow (Before) |
No instruction for visual inspection of individual part. 383_Outflow_Before.pdf |
| Outflow (After) |
OPL provided for visual inspection to educate for proper material inspection. 383_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Anchor pin 8mm |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | done |