QFR No - 8000831919
Defect Details
| NC No. | 8000831919 |
| NC Date | 07/06/2023 |
| NC Submission Date | |
| Part No. | F2DZ03912B |
| Part Name | FORK BOLT-AABM |
| Supplier Name & Code | 100539-N P ENTERPRISES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION- IMPROPER BUFFING OBSERVED |
1. Problem Description
| Defect Description | Buffing step mark on the top face of fork bolt (AABM) |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 440 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@npcindustries.in |
| Plant Head/CEO Email ID | anand@npcindustries.in |
| MD Email ID | ajay@npcindustries.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
1200
|
0
|
0
|
0
|
2200
|
| Check Qty |
1000
|
1200
|
0
|
0
|
0
|
2200
|
| NG Qty |
440
|
300
|
0
|
0
|
0
|
740
|
| Scrap | 0 |
| Rework | 740 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Checked visually |
3. Process Flow
| Process Flow Description |
|---|
| 10 - Raw Material 20 - Cutting and Forging(1st) 30-Forging(2nd) 40-Annealing 50-Phosphating 60 - Forging(3rd) I.D 70-Forging(4th) Hex 80 - CNC(1st) 90 - CNC(2nd) 100 - CNC(3rd) 110 - CNC drilling and Chamfering 120 - Final inspection 130 - Packing & Dispatch 140 - Buffing-1st 150 - Buffing 2nd 160 - Plating |
4. Process Details
| Process / Operation | Buffing |
| Outsource | Yes |
| Machine / Cell | Buffing |
| Machine / Cell No. | Buffing Machine |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled operator used for Buffing operation | Operator observed to be skilled | O |
| Man | Operator unaware of defect | Operator observed to be aware | O |
| Material | Chemical composition not as per Std | Chemical composition observed as per Std | O |
| Tool | Use Wrong Size tool | After verification we found operator was use wrong size of tool | X |
| Method | Rejected material mixed | After verification we found Rejected material was not mix with ok parts | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Step mark observed on fork bolt. |
| Why 2 | Excess material remove from the work pieces. |
| Why 3 | Use High grain size ceramic belt use . |
| Why 4 | Belt size did not define. |
| Why 5 | |
| Root Cause (Occurance) | Ceramic Belt grain size did not define |
Root Cause Analysis (Outflow)
| Why 1 | Could not be detected during Sampling inspection |
| Why 2 | Sampling plan unable to catch defective part |
| Why 3 | Sampling plan inadequate |
| Why 4 | IS 2500 Sampling plan used |
| Why 5 | |
| Root Cause (Outflow) | Sampling plan is not sufficient. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Q- alert to be displayed at buffing station & inspection station. | Mr. Princ | 09/06/2023 | 08/06/2023 | Completed |
| Outflow | 100% inspection for Fork Bolt . | Mr. Deepak | 04/07/2023 | 10/06/2023 | Completed |
| Occurance | Change Ceramic Belt grain size 80 and 120 to 220 and 620 | Mr. Gurpreet Singh | 28/06/2023 | 13/06/2023 | Completed |
| Occurance | use of warn buffing wheel for better finishing. | Mr. Gurpreet Singh | 28/06/2023 | 13/06/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Inspection should be done after buffing. |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | No |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
used of wrong size belt 466_Occurance_Before.png |
| Occurance (After) |
belt replace with wheel and currently using of warn buffing wheel. 466_Occurance_After.png |
| Outflow (Before) |
used of sampling inspection plan 466_Outflow_Before.jpg |
| Outflow (After) |
100% inspection should be done after buffing 466_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Buffing Shop |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, ProcessFlowChart, InspCheckSheet |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | Verified and found ok |