QFR No - 8000823929
Defect Details
| NC No. | 8000823929 |
| NC Date | 20/03/2023 |
| NC Submission Date | |
| Part No. | F2FA01200B |
| Part Name | FORK PIPE RAW K23A (W/O HARDENING) |
| Supplier Name & Code | 101066-TUBE INVESTMENTS OF INDIA LIMI |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-HARDNESS & THICKNESS NG |
1. Problem Description
| Defect Description | 1) Fork pipe Hardness (28±4HRC) observed up to 12 ~15 HRC. 2) Thickness variation observed up to 0.35mm. |
| Detection Stage | Inprocess |
| Problem Severity | Safety |
| NG Quantity | 5 |
| 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 |
52407
|
0
|
0
|
0
|
0
|
52407
|
| Check Qty |
52407
|
0
|
0
|
0
|
0
|
52407
|
| NG Qty |
5945
|
0
|
0
|
0
|
0
|
5945
|
| Scrap | 5945 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % Inspection done by using Eddy Sorter machine in available Qty. 52407 Nos. at ETL End. |
3. Process Flow
| Process Flow Description |
|---|
| Drawing- Tempering-Straightning-Edyy Current Testing-Cutting-Final Inspection. |
4. Process Details
| Process / Operation | Tempering Process |
| Outsource | No |
| Machine / Cell | Online Tempering Machine |
| Machine / Cell No. | 13A106 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Power - 203kw , Speed 16 MPM Speed reduced by 4 MPM | 1. Hardness found 22-25HRC and not matching with failed part Hardness 2. No visual difference | O |
| Machine | Power -200kw , Speed 14 MPM Speed reduced by 6 MPM | 1. Hardness found 22-25HRC and not matching with failed part Hardness 2. No visual difference | O |
| Machine | Tube Jerk: Tube holding 2 -3 sec and repeat the same for 3 times in same tube | Hardness found ok | O |
| Machine | Power -241KW , Speed -20MPM Power increased by 40KW | 1. Hardness found 23-28HRC and not matching with failed part Hardness 2. No visual difference | O |
| Machine | Speed -20mpm , Power -203KW | Hardness found ok | O |
| Machine | Tube Stuck-up: Tube holding time 5- 6 sec | 1. Hardness found 14-15 HRC and matching with failed part Hardness 2. end portion is hardness found | X |
| Machine | Power - 230 KW ,Speed -20MPM Power increased by 30KW | 1. Hardness found 24-28HRC and not matching with failed part Hardness 2. No visual difference | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Pokayoke |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | /JOB ORDER |
7. Root Cause Analysis (Occurance)
| Why 1 | Tube bend during process |
| Why 2 | Tube low hardness |
| Why 3 | Tube low hardness at temering |
| Why 4 | Tube excess tempering |
| Why 5 | Tube struck up at tempering for more than 5 seconds |
| Root Cause (Occurance) | Tube struck up at tempering for more than 5 seconds |
Root Cause Analysis (Outflow)
| Why 1 | Tube bend during the process |
| Why 2 | Tube low hardness |
| Why 3 | NG tube mixed with ok tube |
| Why 4 | No identification of NG tube |
| Why 5 | |
| Root Cause (Outflow) | No identification of NG tube |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Separate bucket provided for NG tubes | Mr. Rajkumar | 30/03/2023 | 30/03/2023 | Completed |
| Occurance | 1. Interlocking of tube struck up (more than 3 seconds) and tempering coil power off | Mr. Rajkumar | 30/03/2023 | 30/03/2023 | Completed |
| Outflow | Auto Paint spray system introduced during tube struck up in tempering line more than 3 seconds | Mr. Rajkumar | 30/03/2023 | 29/03/2023 | Completed |
| Outflow | .Hardness verification point added at tempering stage for each job order | Mr. Rajkumar | 30/03/2023 | 29/03/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Hardness verification added during tempering |
| Inspection Method | Other |
| Other Inspection Method | Hardness verificatio |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | /job order |
10. Evidance of Countermeasure
| Occurance (Before) |
NIL 393_Occurance_Before.pdf |
| Occurance (After) |
1. Interlocking of tube struck up (more than 3 seconds) and tempering coil power off
2. Auto Paint spray system introduced during tube struck up in tempering line more than 3 seconds 393_Occurance_After.pdf |
| Outflow (Before) |
NIL 393_Outflow_Before.pdf |
| Outflow (After) |
1. Hardness verification point added at the tempering stage for each job order
2. Separate buckets provided for NG tubes 393_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Online Tempering machines at PAN TPI |
12. Document Review
| Documents | WISOP, InspCheckSheet |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |