QFR No - 8000827009
Defect Details
| NC No. | 8000827009 |
| NC Date | 22/04/2023 |
| NC Submission Date | |
| Part No. | 520LZ01612 |
| Part Name | SPACER |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | M/CING SHIFT.-MACHINING SHIFT |
1. Problem Description
| Defect Description | Wall thickness variation observed up to 0.15mm. ( Inner dia. drilling cross observed.) |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 351 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@apw3.co.in |
| 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 |
10000
|
0
|
0
|
4000
|
0
|
14000
|
| Check Qty |
10000
|
0
|
0
|
4000
|
0
|
14000
|
| NG Qty |
351
|
0
|
0
|
90
|
0
|
441
|
| Scrap | 441 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done at ETL and in-house pipeline material immediately and defective part removed from OK parts. |
3. Process Flow
| Process Flow Description |
|---|
| 10) RM Inward 20) Parting and Drilling 30) Reamer ID Ø20 40) Chamfering (Both side) 50) Plating (Outsource) 60) Final Inspection 70) Pre-dispatch Inspection 80) Packing & Dispatch |
4. Process Details
| Process / Operation | Parting and Drilling operation |
| Outsource | No |
| Machine / Cell | SE/A/07 |
| Machine / Cell No. | Traub Machine |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Incorrect RM grade | Third part inspection verified for chemical composition and hardness testing as per requirement. | O |
| Method | Checking method wrong | yes part checked by PPG and snap gauge which is not suitable for concentricity. | X |
| Tool | Tool worn out | Tool life for all the tool i.e. forming tool, drill, tap and insert are defined and recorded as per | O |
| Man | Un-skilled operator and inspector | Semi-skilled operator | X |
| Machine | Inadequate check Point in JH check sheet | Monthly JH check sheet available on machine and all the check point is being checked and recorded as | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
7. Root Cause Analysis (Occurance)
| Why 1 | M/CING SHIFT.-MACHINING SHIFT (Concentricity not ok) |
| Why 2 | Improper resting at reamer operation stage |
| Why 3 | Burr/Chip placed inside the reaming fixture. |
| Why 4 | Burr cleaning not done properly. |
| Why 5 | Burr cleaning by wire brush ( need burr cleaning by pneumatic air pressure upto 4 Bar) |
| Root Cause (Occurance) | Burr cleaning by wire brush ( need burr cleaning by pneumatic air pressure upto 4 Bar) |
Root Cause Analysis (Outflow)
| Why 1 | Concentricity not ok part reached at ETL |
| Why 2 | Parts checked wrong by method |
| Why 3 | Parts checked by PPG and snap gauge. |
| Why 4 | Special concentricity checking gauge not available. |
| Why 5 | Checking method design by system. |
| Root Cause (Outflow) | Parts checked wrong by method (Special concentricity checking gauge not available because of Checking method design by system. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Special concentricity checking gauge for Ø20.0 and 22.0 will be provided for 100% checking. on job training given to inspectors and check point added in OPL. | Mr. Shaikh L.N. | 15/05/2023 | 30/05/2023 | Completed |
| Occurance | Pneumatic gun provided along with 4 bar air pressure for reamer fixture cleaning, on job training given to operator and OPL displayed on reamer machine for awareness purpose. | Mr. Datta Pandhre | 08/05/2023 | 25/05/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Parts will be checked by special concentricity gauge in place of PPG and snap gauge. |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
Burr cleaning by wire brush ( need burr cleaning by pneumatic air pressure up to 4 Bar) air pressure for burr removing/cleaning. 429_Occurance_Before.jpg |
| Occurance (After) |
Pneumatic gun provided along with 4 bar air pressure for reamer fixture cleaning. on job training given to operator and OPL displayed on reamer machine for awareness purpose. 429_Occurance_After.jpg |
| Outflow (Before) |
Parts checked by wrong method by PPG and snap gauge (Special concentricity checking gauge not available because of checking method design by system. 429_Outflow_Before.jpg |
| Outflow (After) |
Special concentricity checking gauge for Ø20.0 and 22.0 will be provided for 100% checking. on job training given to inspectors and check point added in the OPL. 429_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 1500 |
| Reason for submission | Control Plans found updated. |