QFR No - 8000824014
Defect Details
| NC No. | 8000824014 |
| NC Date | 21/03/2023 |
| NC Submission Date | |
| Part No. | B2BQ01726O |
| Part Name | SCREW FOR FASTENING CAP - C101CBS |
| Supplier Name & Code | 100846-SANGKAJ ENGINEERING PVT.LTD. |
| ETL Plant | 1156-ETL Disc Brake P'Nagar |
| Defect Details | DIMETER UNDERSIZE-LENGTH SHORT |
1. Problem Description
| Defect Description | Length short pieces mix up issue |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 207 |
| 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 |
37000
|
0
|
0
|
0
|
0
|
37000
|
| Check Qty |
37000
|
0
|
0
|
0
|
0
|
37000
|
| NG Qty |
207
|
0
|
0
|
0
|
0
|
207
|
| Scrap | 207 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done at ETL by supplier. |
3. Process Flow
| Process Flow Description |
|---|
| Wire draw-Cold forging-rolling-HT-plating-FID-PDI-packing- dispatch |
4. Process Details
| Process / Operation | Heat treat |
| Outsource | No |
| Machine / Cell | Continuous mesh belt furnace |
| Machine / Cell No. | Furnace no. 02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Material mixup at HT loading stage | Cause verified | O |
| Man | Material mix-up at packing stage | cause verified | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | as per std |
7. Root Cause Analysis (Occurance)
| Why 1 | Short length pcs found at customer end |
| Why 2 | Similar part of other model found in OK material |
| Why 3 | Both Material having common process like Heat treatment |
| Why 4 | Heat treat is continuous mesh belt ,which is loaded continuously. |
| Why 5 | No gap between in similar parts while loading for heat treatment. |
| Root Cause (Occurance) | WI is inadequate, no any instruction to avoid such kind of mix-up |
Root Cause Analysis (Outflow)
| Why 1 | Short length pcs found at customer end, mixed with regular part. |
| Why 2 | Mixed parts were similar to ok parts. |
| Why 3 | Material is being packed on floor. |
| Why 4 | Similar parts are lying on floor when packing of material. |
| Why 5 | Packing station is not proper. |
| Root Cause (Outflow) | Packing stage is not proper. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Separate and proper stage for packing of material. | Aslam Shaikh | 28/03/2023 | 27/03/2023 | Completed |
| Occurance | Work instruction is provided with training ,to avoid mix-up. | Datta Kale | 28/03/2023 | 27/03/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | Packing method has been changed. |
| 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) |
No instruction has been provided to maintaining gap between similar parts. 392_Occurance_Before.pdf |
| Occurance (After) |
Work instruction is updated , converted into local language and updated for maintaining gap in similar parts. 392_Occurance_After.pdf |
| Outflow (Before) |
Packing of material was being done on shop floor, and other material is lying near by place. 392_Outflow_Before.jpg |
| Outflow (After) |
Packing of material is being done on table and no other material is permitted on table. 392_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Socket head bolts |
12. Document Review
| Documents | PFMEA, WISOP |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | done |