QFR No - 8000827284
Defect Details
| NC No. | 8000827284 |
| NC Date | 24/04/2023 |
| NC Submission Date | |
| Part No. | 520HL00202 |
| Part Name | OIL LOCK COLLAR |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | DIMN.U/SIZE.-ID LESS ISSUE |
1. Problem Description
| Defect Description | Oil lock collar ID less issue |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 101 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | e01cj5hc5pkgorczc3ywsn10.xlsx |
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 |
4000
|
0
|
0
|
4000
|
0
|
8000
|
| Check Qty |
4000
|
0
|
0
|
4000
|
0
|
8000
|
| NG Qty |
101
|
0
|
0
|
0
|
0
|
101
|
| Scrap | 0 |
| Rework | 101 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done immediately at ETL and in-house pipeline material. |
3. Process Flow
| Process Flow Description |
|---|
| 10) RM Inward inspection 20) Parting & Chamfering 30) CNC 1st Set Up 40) Plating Process (Outsource) 50) Inward inspection 60) Storage 70) Final Inspection 80) Pre-dispatch inspection 90) Packing & forwarding |
4. Process Details
| Process / Operation | RM Inward inspection |
| Outsource | Yes |
| Machine / Cell | NA |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Input raw material NG | Input raw material inner diameter observed under size. | X |
| Tool | Insert/Drill/Parting & forming tool worn out | Tool life for all the tool i.e. forming tool, drill, tap and insert are defined and recorded as per | 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 |
| Method | Part/component inspected by wrong method (Vernier caliper ) | Part/component inspected by PPG & bore gauge. | O |
| Man | Un-skilled Operator | Stage wise skill matrix and operator license are evident as per F/HR/06 | 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 | OIL LOCK COLLAR ID under size part reached at ETL |
| Why 2 | RM tube Ø26X18.30 ID under size itself |
| Why 3 | RM defect |
| Why 4 | NO machining for inner diameter |
| Why 5 | By system design |
| Root Cause (Occurance) | NO machining for inner diameter |
Root Cause Analysis (Outflow)
| Why 1 | OIL LOCK COLLAR ID under size part reached at ETL |
| Why 2 | Inadequate part/defect knowledge to operator/inspector. |
| Why 3 | New defect phenomena |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | OPL & Q alert not displayed on machine and final inspection stage and Inadequate part/defect knowledge to operator/inspector. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 100% inspection started after receipt of RM at machining stage, while loading the tube in the machine collet. | Mr. Datta Pandhre | 03/05/2023 | 03/05/2023 | Completed |
| Outflow | OPL & Q alert displayed on machine and final inspection stage and training given to all concerns. | Mr. Shaikh L.N. | 02/05/2023 | 02/05/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection started at final inspection stage by PPG |
| 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) |
Check point not added in the control plan at parting stage . 427_Occurance_Before.jpg |
| Occurance (After) |
100% inspection started after receipt of RM at machining stage while loading the tube in the machine collet. 427_Occurance_After.jpg |
| Outflow (Before) |
Check point not evident in CP. OPL & Q alert not displayed on machine and final inspection stage and Inadequate part/defect
knowledge to operator/inspector. 427_Outflow_Before.jpg |
| Outflow (After) |
Control plan revised and check point added. OPL & Q alert displayed on machine and final inspection stage and training given
to all concerns.
380_Outflow_After. 427_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Reviewed 1000 no`s found ok |