QFR No - 8000827040
Defect Details
| NC No. | 8000827040 |
| NC Date | 22/04/2023 |
| NC Submission Date | |
| Part No. | S3LZ00312B |
| Part Name | SPACER -TVS KING FRONT |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | DIAMETER OVER SIZE-I D OVERSIZE |
1. Problem Description
| Defect Description | Inner dia. found oversize by 0.1 to 0.18 mm. |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 508 |
| Is Defect Repeatative? | Yes |
| 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 |
3500
|
0
|
0
|
1000
|
0
|
4500
|
| Check Qty |
3500
|
0
|
0
|
1000
|
0
|
4500
|
| NG Qty |
508
|
0
|
0
|
162
|
0
|
670
|
| Scrap | 670 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation by Plug gauge |
3. Process Flow
| Process Flow Description |
|---|
| RM Receipt Inspection, RM Storage, Parting and Drilling, Chamfering,Taping,Milling,OD Grinding,Plating,Inward Inspection of Plating,Final Inspection,PDIR,Packing and Dispatch. |
4. Process Details
| Process / Operation | Parting and Drilling |
| Outsource | No |
| Machine / Cell | Traub |
| Machine / Cell No. | 7 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | - | - | O |
| Machine | NG process parameter. | Check sheet verified found OK as per requirement. | O |
| Tool | Wrong Drill used | Resharpening is done on Drill manually | X |
| Method | Drill size verification after drill re-sharpening. | Drill size verified found OK, but no any verification check point after drill re-sharpening. | X |
| Man | Unskilled operator | Operator Level verified, found adequate. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | As per CP |
7. Root Cause Analysis (Occurance)
| Why 1 | ID 9.7+0.2 observed oversized upto 10 mm |
| Why 2 | Drill size observed on higher side after resharpening |
| Why 3 | Drill re-sharpening was in adequate. |
| Why 4 | Drill re-sharpening to be done manually. |
| Why 5 | No any adequate method. |
| Root Cause (Occurance) | No any adequate method available for drill re-sharpening & same results to oversize drilling |
Root Cause Analysis (Outflow)
| Why 1 | ID 9.7+0.2 observed oversized upto 10 mm |
| Why 2 | Not detected during in process inspection |
| Why 3 | sample basis inspection during in-process. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Sample basis inpection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Drill inspection at Setup and Tool change | Production Supervisor | 25/04/2023 | 25/04/2023 | Completed |
| Outflow | 100% inspection at Q gate | QA Supervisor | 25/04/2023 | 25/04/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | - |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | is2500 |
10. Evidance of Countermeasure
| Occurance (Before) |
- 430_Occurance_Before.pdf |
| Occurance (After) |
- 430_Occurance_After.pdf |
| Outflow (Before) |
- 430_Outflow_Before.pdf |
| Outflow (After) |
- 430_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | - |
12. Document Review
| Documents | ControlPlan, InspCheckSheet |
| Specify Other Document | - |
13. Effectiveness Of Action
| Reviewed Quantity | 10 |
| Reason for submission | Corrective action parts submission. |