QFR No - 8000825774
Defect Details
| NC No. | 8000825774 |
| NC Date | 07/04/2023 |
| NC Submission Date | |
| Part No. | F2GN12502B |
| Part Name | MAIN SPRING J1A & J1D |
| Supplier Name & Code | 100180-BHALLA TECHTRAN INDUSTRIES LIM |
| 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 | 201 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@btlsprings.com |
| Plant Head/CEO Email ID | plant1@btlsprings.com |
| MD Email ID | amitbhalla.btl@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
3000
|
0
|
1200
|
0
|
6200
|
| Check Qty |
2000
|
3000
|
0
|
1200
|
0
|
6200
|
| NG Qty |
201
|
12
|
0
|
0
|
0
|
213
|
| Scrap | 0 |
| Rework | 212 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Check the all material lying at customer end, ware house and in plant FG with proper stand on surface plate |
3. Process Flow
| Process Flow Description |
|---|
| Coiling, Stress relieving 1st, End grinding, Shot peening, Stress relieving 2nd, Scragging, Final Inspection, PDI, Packing & Dispatch |
4. Process Details
| Process / Operation | End Grinding |
| Outsource | No |
| Machine / Cell | CNC Grinder |
| Machine / Cell No. | WNJ |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Grinding wheel dressing not proper | Dresser plate worn out | X |
| Man | Unskilled operator | Operator skill level OK | O |
| Material | RM not as per specification | RM found OK | O |
| Tool | Wheel dresser unit not OK | Dresser plate worn out | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 Pcs |
7. Root Cause Analysis (Occurance)
| Why 1 | End grinding was in taper |
| Why 2 | Grinding wheel surface not parallel |
| Why 3 | Grinding wheel dressing was not proper |
| Why 4 | Dresser plate worn out |
| Why 5 | Dresser plate changing freq. not decided |
| Root Cause (Occurance) | Dresser plate changing freq. not decided |
Root Cause Analysis (Outflow)
| Why 1 | Defected parts not detect in PDI |
| Why 2 | Sampling inspection |
| Why 3 | 100% inspection not possible with instruments |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Defected parts not detect due to sampling inspection on PDI stage |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Dresser plate changing freq. decided after 18000 nos. | Rajesh | 10/04/2023 | 10/04/2023 | Completed |
| Outflow | 100% inspection started, Parts stand on surface plate before packing | Rajesh | 11/04/2023 | 11/04/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection started before packing, Parts should be stand on surface plate |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | all |
10. Evidance of Countermeasure
| Occurance (Before) |
PFD & Control plan 400_Occurance_Before.xls |
| Occurance (After) |
Revised PFD & Control plan 400_Occurance_After.xls |
| Outflow (Before) |
Sampling Inspection 400_Outflow_Before.xlsx |
| Outflow (After) |
100 % Inspection, parts should be stand on surface plate 400_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | CNC GRINDING MACHINE |
12. Document Review
| Documents | ControlPlan, WISOP, ProcessFlowChart |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 300 |
| Reason for submission | Verified and found ok |