QFR No - 8000826358
Defect Details
| NC No. | 8000826358 |
| NC Date | 15/04/2023 |
| NC Submission Date | |
| Part No. | S2CW00307B |
| Part Name | D NUT DUKE 200 WITH CANISTER |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | DIAMETER OVER SIZE-O/D OVER SIZE SPE=21.0+0.30 OBS=21.60MM |
1. Problem Description
| Defect Description | DIAMETER OVER SIZE-O/D OVER SIZE SPE=21.0+0.30 OBS=21.60MM |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 499 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
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 |
540
|
0
|
0
|
0
|
0
|
540
|
| Check Qty |
540
|
0
|
0
|
0
|
0
|
540
|
| NG Qty |
499
|
0
|
0
|
0
|
0
|
499
|
| Scrap | 499 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Inspection done with DVC for ETL End Material |
3. Process Flow
| Process Flow Description |
|---|
| RM Receipt & Inspection, Parting and Drilling, CNC I, CNC II, Milling, Deburring, Heat Treatment, Shot Blasting, Powder Coating, Inward Inspection, Final Inspection, PDI, Packing & Forwarding |
4. Process Details
| Process / Operation | 1st Setup CNC |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | 8 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Insert wear out | Insert life defined found OK | O |
| Material | Hard Material | TC verified found OK | O |
| Machine | Machine parameter not OK | Verified and found all parameter within spec | O |
| Method | Coating thickness allowance | OD dimn maintained 21+0.3, No Coating allowance | X |
| Man | Unskilled manpower | Operator level defined, found adequate | O |
| Method | No checkpoint for OD 21+0.3 | Checkpoint added but on sample basis with DVC | X |
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 | as per CP |
7. Root Cause Analysis (Occurance)
| Why 1 | Fitment issue in D Nut Canister Duke 200 |
| Why 2 | OD 21+0.3 mm oversized |
| Why 3 | Dimension maintained 21+0.3 as per CP |
| Why 4 | After coating Diameter oversized |
| Why 5 | No coating allowance kept |
| Root Cause (Occurance) | Diameter observed oversized Due to No coating allowance |
Root Cause Analysis (Outflow)
| Why 1 | Fitment issue in D Nut Canister Duke 200 |
| Why 2 | OD 21+0.3 mm oversized |
| Why 3 | Not detected during inspection |
| Why 4 | sample basis inspection with DVC |
| Why 5 | |
| Root Cause (Outflow) | Sample basis inspection with DVC |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Plating allowance kept 0.2 mm | QA Suprvisor | 20/04/2023 | 18/04/2023 | Completed |
| Outflow | Checking method changed from DVC to Snap Gauge with Controlled Size 21+0.1mm only | Production Supervisor | 20/04/2023 | 18/04/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Checking method changed from DVC to Snap Gauge with Controlled Size 21+0.1mm only |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | IS 2500 |
10. Evidance of Countermeasure
| Occurance (Before) |
No powder coating allowance at machining stage 411_Occurance_Before.pdf |
| Occurance (After) |
Considering powder coating allowance Size put as 21.0+0.1mm at machining stage. 411_Occurance_After.pdf |
| Outflow (Before) |
Before no any inspection done for the OD size 21.0+0.30mm at Final inspection. 411_Outflow_Before.pdf |
| Outflow (After) |
After complaint for the OD Size 21.0+0.30mm inspection started by Snap Gauge 100%. 411_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | D Nut XF1C1 1D1- E92 |
12. Document Review
| Documents | ControlPlan, PFMEA, InspCheckSheet |
| Specify Other Document | - |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | Evidence of Countermeasure not relevant with respect to Action Submitted, Resubmit Again |