QFR No - 8000825772
Defect Details
| NC No. | 8000825772 |
| NC Date | 07/04/2023 |
| NC Submission Date | |
| Part No. | F2GN12502B |
| Part Name | MAIN SPRING J1A & J1D |
| Supplier Name & Code | 101225-HELICAL SPRINGS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-SQUARENESS FOUND NOT OK |
1. Problem Description
| Defect Description | Squareness found 2 mm against the spec of 1 mm |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 483 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | amit.patel@helicalsprings.in |
| Plant Head/CEO Email ID | shaikhmoin@helicalsprings.in |
| MD Email ID | ataneja@helicalsprings.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
6448
|
0
|
0
|
0
|
0
|
6448
|
| Check Qty |
6448
|
0
|
0
|
0
|
0
|
6448
|
| NG Qty |
448
|
0
|
0
|
0
|
0
|
448
|
| Scrap | 0 |
| Rework | 100 |
| Under Deviation | 0 |
| Containment Action |
|---|
| segregate all material at customer end. |
3. Process Flow
| Process Flow Description |
|---|
| Raw Material > Coiling > Stress Relieving - 1 > End Grinding > Shot peening > Scragging > Length, OD & Wavyness Checking > Stress Relieving -2 > Surface Finish Oiling > PDI > Packing & Dispatch. |
4. Process Details
| Process / Operation | Grinding Operation |
| Outsource | No |
| Machine / Cell | Grinding Machine |
| Machine / Cell No. | L4G1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Grinding Plate Misalignment. | Grinding Plate alignment not checked | X |
| Method | Wheel dressing not followed as per defined frequency | Wheel dressing done as per the defined frequency | O |
| Material | As per Drawing | RMTC checked found ok | O |
| Machine | Herdon | Found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | By Spring Standing |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | End Coil Squareness Out of Spec. |
| Why 2 | Spring not loaded straight in Grinding plate |
| Why 3 | Grinding plate position not ok |
| Why 4 | Holes in layer wise Grinding plates not aligned with respect to each other |
| Why 5 | Alignment of holes of three plates checked with insertion of spring |
| Root Cause (Occurance) | No robust method to check the alignment of holes of three plates |
Root Cause Analysis (Outflow)
| Why 1 | End Coil Squareness Out of Spec. |
| Why 2 | Not arrested in inspection |
| Why 3 | Inspection done on sampling basis |
| Why 4 | No 100% inspection defined |
| Why 5 | |
| Root Cause (Outflow) | No 100% inspection defined |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 100% inspection of springs by making the springs stand on surface | Prod. And Quality | 25/03/2023 | 25/03/2023 | Completed |
| Occurance | 1.Alignment of grinding plates holes ensured with the help of rod positioned between grinding plates. [OPL ADDED] 2. Check point of alignment of grinding plates added in grinding setup approval. 3.OPL displayed at Grinding 4.Training provided to the operator and recorded the same | Prod. And Quality | 25/03/2023 | 25/03/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection of springs by making the springs stand on surface |
| Inspection Method | Other |
| Other Inspection Method | By Spring Standing |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 5 |
10. Evidance of Countermeasure
| Occurance (Before) |
Alignment of grinding plates holes ensured with the help of spring insertion in grinding holes 398_Occurance_Before.pdf |
| Occurance (After) |
Alignment of grinding plates holes ensured with the help of rod positioned between grinding plates. 398_Occurance_After.pdf |
| Outflow (Before) |
Sampling Inspection 398_Outflow_Before.pdf |
| Outflow (After) |
100 % inspection by making spring stand 398_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | similar model |
12. Document Review
| Documents | PFMEA, InspCheckSheet |
| Specify Other Document | setup report |
13. Effectiveness Of Action
| Reviewed Quantity | 300 |
| Reason for submission | Verified next 3 lot and found ok |