QFR No - 8000822381
Defect Details
| NC No. | 8000822381 |
| NC Date | 03/03/2023 |
| NC Submission Date | |
| Part No. | 520LW00202 |
| Part Name | SLIDE BUSH 31DIA. |
| Supplier Name & Code | 101164-BBL DAIDO P. LTD |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | BORE DIA. U/SIZE.-PART MIX-UP ISSUE |
1. Problem Description
| Defect Description | Dia 31 slide bush found mix-up |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 25 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | rajamani@bbldaido.com |
| Plant Head/CEO Email ID | rajamani@bbldaido.com |
| MD Email ID | vinod@bbldaido.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
8470
|
3080
|
0
|
0
|
0
|
11550
|
| Check Qty |
8470
|
3080
|
0
|
0
|
0
|
11550
|
| NG Qty |
4
|
0
|
0
|
0
|
0
|
4
|
| Scrap | 4 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation completed available parts at ETL and all other locations |
3. Process Flow
| Process Flow Description |
|---|
| RM receipt - RM Inspection - Slitting - Slitting storage- Welding & Grinding - Size rolling - Facing & Chamfering -Straightening- Blanking and forming - Coining - Final Inspection - Visual inspection - Cleaning and oiling - Packing - Despatch |
4. Process Details
| Process / Operation | Bush manufacturing - 8A line |
| Outsource | No |
| Machine / Cell | Coining Machine , WIP and Inspection packing |
| Machine / Cell No. | 8A |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Defect unable to detect | Similar parts unbale to detect | X |
| Machine | Parts skipped on the Washing basket | found ok | O |
| Method | WIP - Similar parts storage very near | Found near similar parts 33X20 and 36X20 | X |
| Method | 100% Visual inspection not done | On verification 100% is being inspection done | O |
| Method | Inspector Misjudgement | Found OK | O |
| Method | Setting work standard not followed | Found OK- Set up and First off found ok | O |
| Man | Part handling rule not followed | Found Followed | O |
| Machine | Conveyor off during coining machine Off | found ok | O |
| Machine | parts Stuck on machine guard | Found OK | O |
| Method | Inspector Skill level low | Verified found Mr. Venkatesh skill level 4 meeting the requirement | O |
| Method | Inspection methods not adequate | Found OK | 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 | 20 nos |
7. Root Cause Analysis (Occurance)
| Why 1 | WIP - Similar parts storage very near |
| Why 2 | WIP temporary storage area allotted to keep all WIP parts. |
| Why 3 | Keeping similar part with different area not identified |
| Why 4 | Separation of similar parts and control to prevent mix up not adequate. |
| Why 5 | Similar parts identification and separate location not specified. |
| Root Cause (Occurance) | Similar parts identification and separate location not specified. |
Root Cause Analysis (Outflow)
| Why 1 | Defect unable to detect. |
| Why 2 | Both parts are similar in appearance |
| Why 3 | Part size comparison not easy to find out difference.. |
| Why 4 | Both parts are not applicable for batch code identification |
| Why 5 | Automated detection controls not available |
| Root Cause (Outflow) | Automated detection controls not available |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Similar parts location arranged to avoid mix up of parts at WIP | Ramesh san | 30/03/2023 | 29/03/2023 | Completed |
| Occurance | Identification tag modiffied with indicating parts size for better understanding and avoid mix up | Rajamani | 30/03/2023 | 29/03/2023 | Completed |
| Outflow | Poka yoke to be implemented in the automated packing machine by chute setting block and controls | Rajamani | 29/03/2023 | 29/03/2023 | Completed |
| Outflow | Production plan guide introduction that is recommendation as smaller parts to bigger parts reverse bush planning | Rajamani | 30/03/2023 | 29/03/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Poka yoke implemented |
| Inspection Method | Pokayoke |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
WIP Layout not market part size wise to avoid mix up 385_Occurance_Before.pptx |
| Occurance (After) |
Layout marking provided and indicated the size and location 385_Occurance_After.pptx |
| Outflow (Before) |
Poka yoke not available if other bigger size mixed in the lot 385_Outflow_Before.pptx |
| Outflow (After) |
Poka yoke implemented chute width controlled by controller 385_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All other parts 34X20 , 36X20 , 40X20 bushes |
12. Document Review
| Documents | PokayokeCheckSheet, PFMEA, WISOP |
| Specify Other Document | Training sheet |
13. Effectiveness Of Action
| Reviewed Quantity | 300 |
| Reason for submission | Verified next 3 lot and found ok |