QFR No - 8000836624
Defect Details
| NC No. | 8000836624 |
| NC Date | 13/07/2023 |
| NC Submission Date | |
| Part No. | 550FA18433 |
| Part Name | FORK PIPE MACHINED - K11 |
| Supplier Name & Code | 101222-SANGKAJ ENGINEERING PVT LTD- U |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-QM-VL-KDH - THREADING NG |
1. Problem Description
| Defect Description | Threading NG found at incoming |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 108 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | irfan@sangkaj.com |
| Plant Head/CEO Email ID | steel@sangkaj.com |
| MD Email ID | anirudh.2007@hotmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
0
|
0
|
0
|
0
|
1000
|
| Check Qty |
1000
|
0
|
0
|
0
|
0
|
1000
|
| NG Qty |
108
|
0
|
0
|
0
|
0
|
108
|
| Scrap | 108 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation of all pipe line material at customer as well as warehouse and SEPL end. |
3. Process Flow
| Process Flow Description |
|---|
| 10. RM Inward inspection 20.Identification groove 30.Induction hardening 40.Bend removal 50.CNC Turning First 60. CNC turning second 70. Drilling 80.Air Cleaning 90.Packing and Dispatch |
4. Process Details
| Process / Operation | 50. CNC Turning First |
| Outsource | No |
| Machine / Cell | CNC Fork Pipe Cell |
| Machine / Cell No. | Cell no.3 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Gauge Wear out | Gauge Wear out | O |
| Tool | Tool wear out | Insert/tool manufacturer changed | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 per hour |
7. Root Cause Analysis (Occurance)
| Why 1 | Thread undersize (Go not pass) |
| Why 2 | Tool wear out before its life |
| Why 3 | Wrong grade insert taken for use |
| Why 4 | Insert grade/Manufacturer not mentioned in control plan. |
| Why 5 | |
| Root Cause (Occurance) | Due Insert grade/Manufacturer not mentioned in control plan wrong grade insert taken for use. |
Root Cause Analysis (Outflow)
| Why 1 | Thread undersize (Go not pass) not detected |
| Why 2 | Part found ok on gauge |
| Why 3 | Gauge wear out not detected |
| Why 4 | Wear ring gauge not available |
| Why 5 | |
| Root Cause (Outflow) | Wear ring gauge not available |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Add insert grade and Manufacturer in Control plan | Mr. Krushna Fuke | 02/08/2023 | 01/08/2023 | Completed |
| Outflow | Procure wear ring gauge | Mr.Irfan | 30/08/2023 | 08/09/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | Wear ring added |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | Plan |
10. Evidance of Countermeasure
| Occurance (Before) |
Threading insert specification and Make not available 509_Occurance_Before.pdf |
| Occurance (After) |
Threading insert make and grade updated in control plan 509_Occurance_After.pdf |
| Outflow (Before) |
Wear gauge not available 509_Outflow_Before.xlsx |
| Outflow (After) |
wear gauge ordered and made available up to 30.08.23 509_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All fork pipe model |
12. Document Review
| Documents | ControlPlan, WISOP |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 150 |
| Reason for submission | Ok |