QFR No - 8000826277
Defect Details
| NC No. | 8000826277 |
| NC Date | 14/04/2023 |
| NC Submission Date | |
| Part No. | S2HT11707B |
| Part Name | OUTER SPRING POWDER COATED |
| Supplier Name & Code | 101225-HELICAL SPRINGS |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | BEND-BEND |
1. Problem Description
| Defect Description | Taper Coil Observed Bend |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 264 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | amitpatel.24@rediffmail.com |
| 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 |
14160
|
0
|
0
|
0
|
300
|
14460
|
| Check Qty |
14160
|
0
|
0
|
0
|
300
|
14460
|
| NG Qty |
395
|
0
|
0
|
0
|
0
|
395
|
| Scrap | 395 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Segregation done |
3. Process Flow
| Process Flow Description |
|---|
| As per PFD |
4. Process Details
| Process / Operation | Coling |
| Outsource | No |
| Machine / Cell | -- |
| Machine / Cell No. | -- |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | No concentricity check at coiling | No method to check concentricity at coiling | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | VIsual |
| Check Point at Final Inspection | No |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
7. Root Cause Analysis (Occurance)
| Why 1 | Spring bend at small ID side |
| Why 2 | Taper coil at small ID shift |
| Why 3 | Concentricity of spring ID not Ok |
| Why 4 | Concentricity approved by visual Check |
| Why 5 | No Concentricity Gauge Defined at coiling |
| Root Cause (Occurance) | No Concentricity Gauge Defined at coiling |
Root Cause Analysis (Outflow)
| Why 1 | Bend Spring Not arrested in inspection |
| Why 2 | No Check point of Spring Concentricity. |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No Check point of Spring Concentricity. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Concentricity Checking Gauge during Dock Audit | AP | 14/04/2023 | 14/04/2023 | Completed |
| Occurance | Concentricity Checking Gauge introduced at coiling | NK | 14/04/2023 | 17/04/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Concentricity Checking Gauge during Dock Audit |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
10. Evidance of Countermeasure
| Occurance (Before) |
No Gauge introduced before 412_Occurance_Before.pdf |
| Occurance (After) |
Concentricity gauge Introduced 412_Occurance_After.pdf |
| Outflow (Before) |
No Gauge introduced before 412_Outflow_Before.pdf |
| Outflow (After) |
Concentricity gauge Introduced 412_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | K1 Old |
12. Document Review
| Documents | PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | No Defect Reported after Action |