QFR No - 8000825775
Defect Details
| NC No. | 8000825775 |
| NC Date | 07/04/2023 |
| NC Submission Date | |
| Part No. | 520KH02402 |
| Part Name | REBOUND SPRING(949508058) |
| Supplier Name & Code | 100185-HELICAL SPRINGS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-OUTER DIA OVERSIZE |
1. Problem Description
| Defect Description | Outer dia found oversize by 1 mm |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 181 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | Prabhat@helicalsprings.in |
| Plant Head/CEO Email ID | awadhwa@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 |
7000
|
0
|
0
|
0
|
0
|
7000
|
| Check Qty |
7000
|
0
|
0
|
0
|
0
|
7000
|
| NG Qty |
181
|
0
|
0
|
0
|
0
|
181
|
| Scrap | 181 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % material segregation done at Customer end. |
3. Process Flow
| Process Flow Description |
|---|
| RM INSP --> COILING --> SR1 --> GRINDING --> SHOT PEENING --> SR2 --> FINAL INSPECTION --> OILING |
4. Process Details
| Process / Operation | COILING, FINAL INPSECTION |
| Outsource | No |
| Machine / Cell | COILING, FINAL INSPECTION |
| Machine / Cell No. | HTC 80 CF |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Wire Dia wrong used | wire Dia check for 2402 Found ok | X |
| Machine | Ovality in the Spring OD | Spring OD check & Found ok | X |
| Method | Wrong Model parts Mix up | Physically check & Found wrong model mix up | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | As per Lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Outer Dia Over size Issue |
| Why 2 | Defected parts Observed with Diff. wire dia ( Another Model ) |
| Why 3 | Wrong model part mix up in packing stage |
| Why 4 | Diff diff model parts packing done on Common packing table |
| Why 5 | No rule defined Related to packing |
| Root Cause (Occurance) | Diff Diff model parts packing done on Common packing table , No rule defined related to packing |
Root Cause Analysis (Outflow)
| Why 1 | Defect Not detect during PDI inspection |
| Why 2 | PDI Sampling Insp qty Less, N=5 Nos |
| Why 3 | No Doc audit System for Final dispatch pats |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No Doc audit System for Final dispatch pats |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Rule defined for packing Only one model parts packing in one time , Before another model packing operator finish the previous Model packing & Ensure | Pradeep sharma | 10/04/2023 | 19/04/2023 | Completed |
| Outflow | Sampling Inspection Qty Increase to 20 Nos Visual against 5 Nos & Dock audit to be implemented | Bharat Pathak | 10/04/2023 | 19/04/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No change in inspection system only sampling inspection freq Increase |
| Inspection Method | Other |
| Other Inspection Method | Dock audit implement |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 20 Nos per |
10. Evidance of Countermeasure
| Occurance (Before) |
Before rule not defined 401_Occurance_Before.pdf |
| Occurance (After) |
Rule defined for packing operation 401_Occurance_After.pdf |
| Outflow (Before) |
Before sampling insp qty 05 Nos in PDI 401_Outflow_Before.pdf |
| Outflow (After) |
After sampling Insp Qty Increase 20 Nos in PDI 401_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | plant 104 |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | Rule defined & OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |