QFR No - 8000833477
Defect Details
| NC No. | 8000833477 |
| NC Date | 20/06/2023 |
| NC Submission Date | |
| Part No. | S1GD01726B |
| Part Name | INNER TUBE CHAMFERED K0LA |
| Supplier Name & Code | 101273-SAPTAGIRI ENGINEERING PRIVATE |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | LESS CHAMFER-CHAMFER NG |
1. Problem Description
| Defect Description | ID gauge not qualifying (Chamfer NG and bend). |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 90 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@saptagirigroup.in |
| Plant Head/CEO Email ID | production@saptagirigroup.in |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
3000
|
3000
|
0
|
0
|
2000
|
8000
|
| Check Qty |
3000
|
3000
|
0
|
0
|
2000
|
8000
|
| NG Qty |
90
|
0
|
0
|
0
|
0
|
90
|
| Scrap | 0 |
| Rework | 90 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % material verified by visual |
3. Process Flow
| Process Flow Description |
|---|
| Raw Tube + Cutting + Both Side chamfer + Inspection |
4. Process Details
| Process / Operation | Chamfer |
| Outsource | No |
| Machine / Cell | 01 |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Clamp loosed | No Rigid clamping provided | X |
| Man | Inspector not aware | Inspector not aware about the chamfer | X |
| Tool | Insert Ware out or broken | No Insert warn out and broken | O |
| Machine | Uneven tube cutting done | No uneven cutting done its parallelism observed within 0.1 mm | 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 | Less Chamfer / Chamfer Uneven |
| Why 2 | W.r.t. center outer tube clamping alignment disturb |
| Why 3 | O/t Clamping plate loosed |
| Why 4 | Capsule slot given for bolt locking of the clamping plate |
| Why 5 | |
| Root Cause (Occurance) | Capsule slot given for bolt locking of the clamping plate |
Root Cause Analysis (Outflow)
| Why 1 | Less Chamfer / Chamfer Uneven |
| Why 2 | Inspector Not aware about defect |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspector Not aware about defect |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Awareness training given to inspector | Mr. Dhiraj Patil | 27/06/2023 | 26/06/2023 | Completed |
| Occurance | Rigid bolt engage with clamping plate including spring tension washer to avoided clamping plate loosed issue | Mr. Pravin Jonwal | 27/06/2023 | 26/06/2023 | Completed |
| Occurance | For verification of O/t clamping plate point has added in daily machine check sheet | Mr. Pravin Jonwal | 27/06/2023 | 26/06/2023 | Completed |
| Outflow | 100 % visul inspection started as per one point lesson and Q alert Display at work place | Mr. Dhiraj Patil | 27/06/2023 | 26/06/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | Na |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Implementation & Action for Less chamfer 491_Occurance_Before.pptx |
| Occurance (After) |
Implementation & Action for Less chamfer 491_Occurance_After.pptx |
| Outflow (Before) |
Implementation & Action for Less chamfer 491_Outflow_Before.pptx |
| Outflow (After) |
Implementation & Action for Less chamfer 491_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All type of Inner Tube |
12. Document Review
| Documents | PokayokeCheckSheet |
| Specify Other Document | Na |
13. Effectiveness Of Action
| Reviewed Quantity | 3 |
| Reason for submission | chamfer NG |