QFR No - 8000828496
Defect Details
| NC No. | 8000828496 |
| NC Date | 09/05/2023 |
| NC Submission Date | |
| Part No. | F2GN22102B |
| Part Name | MAIN SPRING - J1C2 FF |
| Supplier Name & Code | 101225-HELICAL SPRINGS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-OVERALL LENGTH OVERSIZE |
1. Problem Description
| Defect Description | Overall length found oversize by 7 mm. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 143 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | amit.patel@helicalsprings.com |
| Plant Head/CEO Email ID | shaikhmoin@helicalsprings.in |
| MD Email ID | ataneja@helicalsprings.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
3000
|
0
|
0
|
5000
|
0
|
8000
|
| Check Qty |
3000
|
0
|
0
|
5000
|
0
|
8000
|
| NG Qty |
143
|
0
|
0
|
0
|
0
|
143
|
| Scrap | 0 |
| Rework | 143 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation of Total stock completed |
3. Process Flow
| Process Flow Description |
|---|
| RM receipt - Coiling- SR1-Grinding- Shot peening- scragging- 100% length checking- SR2-oiling-PDI |
4. Process Details
| Process / Operation | 100% Checking |
| Outsource | No |
| Machine / Cell | Length Checking |
| Machine / Cell No. | 1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Rework sample mix | only one yellow bin used | 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 | 5/lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Length oversize observed at customer end |
| Why 2 | Length oversize sample mix with Ok lot |
| Why 3 | length Oversize material kept in green bin |
| Why 4 | yellow bin at use was only 1 |
| Why 5 | No extra yellow bin used by operator for more qty of RW |
| Root Cause (Occurance) | No extra yellow bin used by operator for more qty of RW |
Root Cause Analysis (Outflow)
| Why 1 | Length oversize observed at customer end |
| Why 2 | Mix up of RW samples occurred after 100% sorting |
| Why 3 | - |
| Why 4 | - |
| Why 5 | - |
| Root Cause (Outflow) | Mix up of RW samples occurred after 100% sorting |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | OPL displayed for usage of yellow bins only for RW | Prod | 29/04/2023 | 29/04/2023 | Completed |
| Outflow | OPL displayed for usage of yellow bins only for RW. Training provided | Prod | 29/04/2023 | 29/04/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | no |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
10. Evidance of Countermeasure
| Occurance (Before) |
Operator used Green bin to keep extra RW material 446_Occurance_Before.pdf |
| Occurance (After) |
OPL displayed for using only Yellow bin 446_Occurance_After.pdf |
| Outflow (Before) |
Operator used Green bin to keep extra RW material 446_Outflow_Before.pdf |
| Outflow (After) |
Training Provided to operator 446_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Items |
12. Document Review
| Documents | AuditCheckSheet |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 300 |
| Reason for submission | ok |