QFR No - 8000825753
Defect Details
| NC No. | 8000825753 |
| NC Date | 08/04/2023 |
| NC Submission Date | |
| Part No. | F2PH02212B |
| Part Name | COVER CAP (Ø33 SPD) |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | HIGHT U/SIZE.-22 MM DIA UINDER SIZE |
1. Problem Description
| Defect Description | HIGHT U/SIZE.-22 MM DIA UINDER SIZE |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 22 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | 42ckgm3bbcuzzla25ogbxw3a.jpg |
Supplier Communication Details
| Quality Head Email ID | quality@sharp-engineers.com |
| Plant Head/CEO Email ID | kurund.ma@sharp-engineers.com |
| MD Email ID | urkhandelwal@sharp-engineers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
3000
|
0
|
0
|
500
|
1000
|
4500
|
| Check Qty |
3000
|
0
|
0
|
500
|
1000
|
4500
|
| NG Qty |
22
|
0
|
0
|
0
|
7
|
29
|
| Scrap | 29 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done for ETL end Material & FG+WIP material 100% verified. |
3. Process Flow
| Process Flow Description |
|---|
| RM Receipt Inspection & Storage, Blank Cutting & Drilling, Milling, CNC-I, CNC-II, Grinding, Plating, Inward Inspection, Final Inspection, PDI, Packing & Forwarding. |
4. Process Details
| Process / Operation | Ist Setup |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | 8 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Worn Out | Observed Ok | O |
| Machine | Machine Parameter variation | Observed OK | O |
| Material | - | - | O |
| Method | Wrong loading of parts | Observed chips / burr accumulation in jaw | X |
| Man | Unskilled | Observed ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | DVC |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | IS2500.1 |
7. Root Cause Analysis (Occurance)
| Why 1 | Wrong loading of parts |
| Why 2 | Part position was not OK |
| Why 3 | Due to Part resting was incomplete in jaw |
| Why 4 | Burr accumulation on Resting face |
| Why 5 | Less space for burr removal in V-Jaw |
| Root Cause (Occurance) | Burr accumulation on Resting face due to less space for burr/chips removal |
Root Cause Analysis (Outflow)
| Why 1 | HEIGHT U/SIZE part observed at customer end |
| Why 2 | Not detected during inprocess inspection |
| Why 3 | Sample basis inspection with DVC |
| Why 4 | Unavailability of gauge |
| Why 5 | |
| Root Cause (Outflow) | Sample basis inspection with gauge |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | V Jaw are replaced by T Jaw | Mr. Ingole DN | 12/04/2023 | 11/04/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Length Gauge Implemented |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | - |
10. Evidance of Countermeasure
| Occurance (Before) |
- 405_Occurance_Before.jpg |
| Occurance (After) |
- 405_Occurance_After.jpeg |
| Outflow (Before) |
- 405_Outflow_Before.xls |
| Outflow (After) |
- 405_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Valve Retainer SPD 31,37 |
12. Document Review
| Documents | ControlPlan, PFMEA, InspCheckSheet |
| Specify Other Document | - |
13. Effectiveness Of Action
| Reviewed Quantity | 8500 |
| Reason for submission | All part 22 mm diameter found ok |