QFR No - 8000823619
Defect Details
| NC No. | 8000823619 |
| NC Date | 17/03/2023 |
| NC Submission Date | |
| Part No. | 550LG06702 |
| Part Name | SEAT PIPE-(HMS-30 & HMP-30) |
| Supplier Name & Code | 100929-HARSHAD ENGINEERING COMPANY |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | THREADING NOT OK-HALF THREAD |
1. Problem Description
| Defect Description | Oil leakage due to half thread in seat pipe |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 2 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qaharshad@miteshauto.com |
| Plant Head/CEO Email ID | qaharshad@miteshauto.com |
| MD Email ID | auto.mitesh@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
4800
|
0
|
0
|
2500
|
0
|
7300
|
| Check Qty |
4800
|
0
|
0
|
2500
|
0
|
7300
|
| NG Qty |
2
|
0
|
0
|
0
|
0
|
2
|
| Scrap | 0 |
| Rework | 2 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % sorting done for ETL End, HEC WIP & FG material |
3. Process Flow
| Process Flow Description |
|---|
| Cutting-Draw-Forging(Head Formation)-Rough Grinding-CNC (Head, Boring & Tapping)-Punching-Finish Grinding-Final Inspection-Packing-Dispatch |
4. Process Details
| Process / Operation | Tapping |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | 140 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Hyd. Oil Seal brake | Hyd. Oil Seal observed in brake condition | O |
| Tool | Tap broken | Tap found ok | X |
| Man | Unskilled operator | Skilled operator | X |
| Method | Improper loading | Loading found proper (Complete resting) | X |
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 | Tap not perform for complete threading length |
| Why 2 | Tap not reached up to complete thread length min. 14 mm |
| Why 3 | Part not clamp at correct position upto head back face |
| Why 4 | Part clamping unit declamp/malfunction at the time setting of auto to manual cycle |
| Why 5 | |
| Root Cause (Occurance) | Collet clamping unit not properly work because hydraulic oil seal gets break and oil pressure drop down |
Root Cause Analysis (Outflow)
| Why 1 | Incomplete Tapping |
| Why 2 | Only Threading presence checked |
| Why 3 | Not aware about Incomplete Threading |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | 100 % Inspection not done for Threading length. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | OPL displayed & Awareness given about threading incomplete | Vaibhav Shirsath | 12/03/2023 | 12/03/2023 | Completed |
| Occurance | Collet holder assly hydraulic oil seal changed | Yogesh Ugle | 15/03/2023 | 16/03/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | 100% Inspection done to ensure complete threading length |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Hydraulic oil seal broken 388_Occurance_Before.jpg |
| Occurance (After) |
Hydraulic oil seal replaced by new one 388_Occurance_After.jpg |
| Outflow (Before) |
NO check point for oil seal condition checking 388_Outflow_Before.pdf |
| Outflow (After) |
Check point added for oil seal condition checking Quarterly 388_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | SPM Machines |
12. Document Review
| Documents | PMCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |