QFR No - 8000834882
Defect Details
| NC No. | 8000834882 |
| NC Date | 28/06/2023 |
| NC Submission Date | |
| Part No. | S2AB04412B |
| Part Name | PRELOAD ADJUSTER |
| Supplier Name & Code | 101273-SAPTAGIRI ENGINEERING PRIVATE |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | WELDING NOT OK-WELDING DEFECT |
1. Problem Description
| Defect Description | Welding NG concern.- Welding incomplete, Blow holes, etc. |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 228 |
| 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 |
2000
|
0
|
0
|
0
|
0
|
2000
|
| Check Qty |
2000
|
0
|
0
|
0
|
0
|
2000
|
| NG Qty |
228
|
0
|
0
|
0
|
0
|
228
|
| Scrap | 228 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % material verified |
3. Process Flow
| Process Flow Description |
|---|
| Raw material welding + sheet shearing + Blanking + U bending + First rounding + Second rounding + CO2 welding (single spot) + CO2 welding (Full run) + Weld bead turning & grinding + Buffing + Parting & ID chamfer + Single notch + First flaring + Second flaring + Restracking + OD trimming & 8 nos notching + Face deburring + Buffing + Fe Zn plating + Final inspection + Packing/ storing. |
4. Process Details
| Process / Operation | Co2 welding opeartion |
| Outsource | No |
| Machine / Cell | 01 |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Round Bending not uniform (Circular) | Round bending observe uniform ( Circular ) | O |
| Method | Sample basis Inspection | While welding and buffing operation only do the sample basis inspection | X |
| Machine | Excess welding outside the gap | No Excess buffing observed | O |
| Machine | Uneven round bending | Height variation in both side as well as uneven gap | X |
| Machine | Round bending gap uneven | In a few part observed uneven gap at top side less ( 0.54 mm ) and bottom side more (1.44 mm | X |
| Machine | Uneven Welding | Welding run verified and observed evenly ( In straight line ) | X |
| Machine | Gap not filled by welding | Gap fully filled by welding operation | O |
| Machine | Excess buffing on welding bead area | No Excess buffing on welding line | O |
| Man | Less awareness | Operator and inspector not aware about the weld line open | 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 | Welding Open after buffing operation |
| Why 2 | Uneven welding fusion or uneven welding filling done |
| Why 3 | Uneven welding gap |
| Why 4 | Uneven round bending |
| Why 5 | Ram entry less or raw material spring back |
| Root Cause (Occurance) | 1. Uneven round bending / Round bending gap uneven 2. Ram entry less or raw material spring back |
Root Cause Analysis (Outflow)
| Why 1 | Welding Open after buffing operation |
| Why 2 | No Inspection after the buffing operation. |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No Inspection after the buffing operation. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 100% inspection starts after welding operation. | Mr. Munja Hore | 30/06/2023 | 29/06/2023 | Completed |
| Occurance | Draw route process to be introduce instead of welding process. | Mr. Ramdas Chavan | 30/06/2023 | 29/06/2023 | Completed |
| Outflow | Q-Alert display at Final inspection and welding stage. | Mr. Munja Hore | 30/06/2023 | 29/06/2023 | Completed |
| Outflow | for ID verification Gauge provided after round bending and re stacking | Mr. Munja Hore | 30/06/2023 | 29/06/2023 | Completed |
| Occurance | Re stacking operation started after round bending to uneven gap | Mr. Ramdas Chavan | 30/06/2023 | 29/06/2023 | Completed |
| Occurance | Before Welding operation 100% inspection starts for uneven round bend. | Mr. Munja Hore | 30/06/2023 | 29/06/2023 | Completed |
| Outflow | 200% Inspection started along with marking at inner side at Final Inspection | Mr. Munja Hore | 30/06/2023 | 29/06/2023 | Completed |
| Outflow | Training given concern operator and inspector for uneven bending and welding open after the buffing process. | Mr. Munja Hore | 30/06/2023 | 29/06/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NA |
| 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) |
Action plan 501_Occurance_Before.pptx |
| Occurance (After) |
Action plan 501_Occurance_After.pptx |
| Outflow (Before) |
Comparison of welded and without welded parts 501_Outflow_Before.pdf |
| Outflow (After) |
Comparison of welded and without welded parts 501_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Other adjuster also ( Re- J1a) |
12. Document Review
| Documents | ControlPlan, PFMEA, ProcessFlowChart |
| Specify Other Document | Comparison report |
13. Effectiveness Of Action
| Reviewed Quantity | 10 |
| Reason for submission | Ok |