QFR No - 8000827041
Defect Details
| NC No. | 8000827041 |
| NC Date | 22/04/2023 |
| NC Submission Date | |
| Part No. | S3GV00112B |
| Part Name | FIX NUT |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | LENGTH UNDERSIZE-WIDTH O/S AND U/S |
1. Problem Description
| Defect Description | Total length observed oversize & undersize. This concern repeated many times before. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 500 |
| 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 |
8000
|
0
|
0
|
5000
|
0
|
13000
|
| Check Qty |
8000
|
0
|
0
|
5000
|
0
|
13000
|
| NG Qty |
500
|
0
|
0
|
120
|
0
|
620
|
| Scrap | 0 |
| Rework | 620 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done immediately for all the ETL and pipeline material. |
3. Process Flow
| Process Flow Description |
|---|
| 10) RM Inspection 20) Parting, Forming & Drilling 30) Chamfer Ø 8.10 40) Tapping M8X1.25 6H 50) Semi-finished part inspection 60) Plating process (Outsource) 70) Final Inspection 80) 90) Pre-dispatch inspection 100) Packing and dispatch. |
4. Process Details
| Process / Operation | Parting, Forming and Drilling |
| Outsource | Yes |
| Machine / Cell | Traub Machine cell |
| Machine / Cell No. | SE/A/05 |
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 | Wrong checking method/sample size. | Checking done by SESG for sampling basis inspection as per IS:2500 | O |
| Tool | Tool worn out | Tool life for all the tool i.e. forming tool, drill, tap and insert are not defined & not recorded. | X |
| Man | Un-skilled Operator | Stage wise skill matrix and operator license ar evident as per F/HR/06 | O |
| 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 | 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 | DIM 15.0+/-0.1 OVER SIZE. |
| Why 2 | Parting tool worn out. |
| Why 3 | Parting tool worn out earlier than defined frequency 300/sharpening |
| Why 4 | Tool life not getting as per defined tool life |
| Why 5 | Coolant concentration is not being monitored. |
| Root Cause (Occurance) | Parting tool worn out earlier than defined frequency 300/sharpening, because coolant concentration is not being monitored. |
Root Cause Analysis (Outflow)
| Why 1 | DIM. 15.0+/-0.1 over size part reached at ETL |
| Why 2 | Not detected at final inspection stage. |
| Why 3 | Sampling basis inspection as per IS 2500 |
| Why 4 | Sample size defined by system. |
| Why 5 | |
| Root Cause (Outflow) | Sampling basis inspection as per IS:2500, No 100% inspection for Total length 15.0+/-0.1mm |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Tool life re-defined 200/sharpening for parting tool and being monitored as per F/PROD/07. on job training given to operator as per F/HR/05 | Mr. Datta Pandhre | 03/05/2023 | 03/05/2023 | Completed |
| Outflow | 100% inspection started as per revised control plan and checking is being done by SESG for inspection. OPL displayed at final inspection stage and on job training given to operator. | Mr. Shaikh L.N. | 03/05/2023 | 03/05/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection started for dimension 15.0+/-0.1mm |
| Inspection Method | 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) |
Parting tool worn out earlier than defined frequency 300/sharpening, because coolant concentration is not being monitored. 432_Occurance_Before.jpg |
| Occurance (After) |
Tool life re-defined 200/sharpening for parting tool and being monitored as per F/PROD/07. on job training given to operator as per F/HR/05 432_Occurance_After.jpg |
| Outflow (Before) |
Sampling basis inspection as per IS:2500, No 100% inspection for Total length 15.0+/-0.1mm 432_Outflow_Before.jpg |
| Outflow (After) |
100% inspection started as per revised control plan and checking is being done by SESG for inspection. OPL displayed at final inspection stage and on job training given to operator. 432_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | FIX NUT (Pulsar Model) part number (520DU00102) |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 10 |
| Reason for submission | Corrective action parts submission. |