QFR No - 8000827285
Defect Details
| NC No. | 8000827285 |
| 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 | HIGHT U/SIZE.-TOTAL LENGHT LESS |
1. Problem Description
| Defect Description | Oil lock collar total length less issue |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 12 |
| 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 |
5000
|
5000
|
0
|
2000
|
0
|
12000
|
| Check Qty |
5000
|
5000
|
0
|
2000
|
0
|
12000
|
| NG Qty |
12
|
0
|
0
|
1
|
0
|
13
|
| Scrap | 13 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done at ETL and in-house FG stock for to avoid further difficulties. |
3. Process Flow
| Process Flow Description |
|---|
| 1) RM inward inspection 2) Parting and chamfering 3) CNC 1st 4) Plating process (outsource-Pranav coating) 5) Inward inspection 6) Storage 7) Final Inspection 8) Pre-dispatch Inspection 9) Packing & forwarding |
4. Process Details
| Process / Operation | CNC 1st |
| Outsource | No |
| Machine / Cell | CNC Machine Shop |
| Machine / Cell No. | SE/CNC/03 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Checking method by attribute type height gauge | Checking done by vernier caliper | X |
| Material | Input material under size | Yes, input material observed under size | 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 |
| Tool | Parting tool and insert worn out | Tool life for all the tool i.e. parting tool and insert are defined and recorded as per F/PROD/07 | 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 | HIGHT U/SIZE.-TOTAL LENGHT LESS |
| Why 2 | INPUT MATERIAL OF CNC MACHINE UNDER SIZE |
| Why 3 | TAPER OBSERVED IN THE INPUT PART |
| Why 4 | INCOREECT TOOL SETTING BY NEW OPERATOR |
| Why 5 | STAGE WISE SKILL MATRIX NOT FOLLOWED. SEMI-SKILLED OPERATOR. |
| Root Cause (Occurance) | STAGE WISE SKILL MATRIX NOT FOLLOWED. SEMI-SKILLED OPERATOR. AND TRAINING NOT GIVEN TO OPERATOR. |
Root Cause Analysis (Outflow)
| Why 1 | HIGHT U/SIZE.-TOTAL LENGHT LESS |
| Why 2 | SAMPLING BASIS INSPECTION AS PER IS:2500 BY VERNIER CALIPER |
| Why 3 | NO 100% INSPECTION BY ATTRIBUTE TYPE GAUGE |
| Why 4 | CHECKING METHOD DEFINED BY SYSTEM |
| Why 5 | |
| Root Cause (Outflow) | INSPECTION DONE BY SAMPLING BASIS AS PER IS:2500, 100% INSPECTION NOT DONE |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | STAGE WISE SKILL MATRIX UPDATED AND TRAINING GIVEN TO OPERATOR, AND OPERATOR DEFINED AS PER SKILL REQUIREMENT. | MR. DATTA PANDHRE | 03/05/2023 | 03/05/2023 | Completed |
| Outflow | INSPECTION STARTED 100% BY ATTRIBUTE TYPE GAUGE AND CONTROL PLAN UPDATED | MR, SHAIKH LAIK | 03/05/2023 | 03/05/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | INSPECTION STARTED BY ATTRIBUTE TYPE GAUGE IN PLACE OF VERNIER CALIPER. |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
STAGE WISE SKILL MATRIX NOT FOLLOWED. SEMI-SKILLED OPERATOR. AND TRAINING NOT GIVEN TO OPERATOR. 426_Occurance_Before.jpg |
| Occurance (After) |
STAGE WISE SKILL MATRIX UPDATED AND TRAINING GIVEN TO OPERATOR, AND OPERATOR DEFINED AS PER SKILL REQUIREMENT. 426_Occurance_After.jpg |
| Outflow (Before) |
NO 100% INSPECTION BY ATTRIBUTE TYPE GAUGE 426_Outflow_Before.jpg |
| Outflow (After) |
INSPECTION STARTED 100% BY ATTRIBUTE TYPE GAUGE AND CONTROL PLAN UPDATED 426_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | OIL LOCK COLLAR K-60 |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | Reviewed 500 no`s found ok |