QFR No - 8000833966
Defect Details
| NC No. | 8000833966 |
| NC Date | 23/06/2023 |
| NC Submission Date | |
| Part No. | F2FA15933M |
| Part Name | FORK PIPE MACHINED (K19 DRUM FF) |
| Supplier Name & Code | 100634-TATA STEEL LIMITED |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | DIMN.U/SIZE.-DIM. U/D OB 8.5 AGINST 11MM |
1. Problem Description
| Defect Description | Fitment Issue : DIMENSION UNDERSIZE.-OBSERVATION 8.50 MM AGAINST 11.00 MM |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 215 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | ri0exybddt0kzupjmkggm1ck.docx |
Supplier Communication Details
| Quality Head Email ID | bipldholpur@gmail.com |
| Plant Head/CEO Email ID | harsh.pareek@tatasteel.com |
| MD Email ID | Praveens@tatasteel.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
500
|
0
|
0
|
0
|
200
|
700
|
| Check Qty |
500
|
0
|
0
|
0
|
200
|
700
|
| NG Qty |
100
|
0
|
0
|
0
|
15
|
115
|
| Scrap | 15 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % Inspection done at ETL and next lots to be supplied only after 100% inspection at TSL end. |
3. Process Flow
| Process Flow Description |
|---|
| CNC 1st set up (Threading) |
4. Process Details
| Process / Operation | CNC Turning |
| Outsource | No |
| Machine / Cell | CNC- Marshall |
| Machine / Cell No. | 03 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | No Probable root cause related to material | No Probable root cause related to material | O |
| Tool | No Probable root cause related to material | No Probable root cause related to material | O |
| Man | No Probable root cause related to material | No Probable root cause related to material | O |
| Machine | Hydraullic Pressure Variation | Hydraulic Oil, Internal Leakage in chuck Cylinder | X |
| Method | Lot of sampling was small | Due to small lot size , Defected Pieces can Skip | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 |
7. Root Cause Analysis (Occurance)
| Why 1 | Fork pipe K19 of Dim under size |
| Why 2 | Hydraullic Oil Presssure Varry |
| Why 3 | Hydraulic Oil, Internal Leakage in chuck Cylinder |
| Why 4 | No Check Point in System |
| Why 5 | |
| Root Cause (Occurance) | Hydraullic oil Internally leakage in Chuck Cylinder due to this Pressure Varry |
Root Cause Analysis (Outflow)
| Why 1 | Fork pipe K19 of Dim under size |
| Why 2 | Not detected in, Inhouse Inspection |
| Why 3 | Lot of sampling was small ( 5 Pcs Hourly) |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Lot of sampling was small ( 5 Pcs Hourly) |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1- check Point added in daily Maintenance check sheet | QA | 12/05/2023 | 12/05/2023 | Completed |
| Outflow | 1.-Lot of Sampling Increases From 5 pcs Hourly to 25 Pcs Hourly 2- Given OPL On this Problem | QA Supervisor | 12/05/2023 | 12/05/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Lot of Sampling Increases ( From 5 pcs Hourly to 25 Pcs Hourly ) |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 |
10. Evidance of Countermeasure
| Occurance (Before) |
NO CHECK POINT DAILY PM CHECKLIST 492_Occurance_Before.jpg |
| Occurance (After) |
CHECK POINT ADDED INDAILY PM CHECKLIST 492_Occurance_After.jpg |
| Outflow (Before) |
05 Pcs Checked Hourly 492_Outflow_Before.jpg |
| Outflow (After) |
25 Pcs Checked Hourly 492_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | ALL CNC MACHINE |
12. Document Review
| Documents | ControlPlan, PMCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 2000 |
| Reason for submission | OK |