QFR No - 8000839662
Defect Details
| NC No. | 8000839662 |
| NC Date | 07/08/2023 |
| NC Submission Date | |
| Part No. | S1HT05507B |
| Part Name | OUTER SPRING - K1JF |
| Supplier Name & Code | 101225-HELICAL SPRINGS |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | DIMETER UNDERSIZE-ID LESS ISSUE |
1. Problem Description
| Defect Description | K1JF Outer spring ID less issue |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 2 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | vegwl3chpj0cbxq1xrhmexwa.jpg |
Supplier Communication Details
| Quality Head Email ID | shaikhmoin@helicalsprings.in |
| Plant Head/CEO Email ID | shaikhmoin@helicalsprings.in |
| MD Email ID | ataneja@helicalsprings.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
0
|
0
|
1200
|
1000
|
4200
|
| Check Qty |
2000
|
0
|
0
|
1200
|
1000
|
4200
|
| NG Qty |
2
|
0
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| We Have Checked All At M/s Helical End Material Found OK. |
3. Process Flow
| Process Flow Description |
|---|
| Coiling>Stress-relieving-1>End Grinding>Shot-peening>Scragging>100% E1, E2 & Length Checking>ID Checking>Stress-Relieving-2>Powder Coating>Final Inspection>Packing>Dispatch. |
4. Process Details
| Process / Operation | 100% ID Checking |
| Outsource | No |
| Machine / Cell | Plain Plug Gauge |
| Machine / Cell No. | - |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Setup spring not specific location. | Location to be defined for setup spring. | X |
| Man | Unskilled Operator | Skill matrix checked found ok | O |
| Machine | Machine check Sheet not followed | CLIT verified found ok | O |
| Material | Material Grade | RMTC verified found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Inner Diameter Under Size |
| Why 2 | RM Coil Change Initial Parts Mix-up |
| Why 3 | No Location Defined for Coil Change Initial Parts |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | RM Coil Change Initial Parts Mix-up |
Root Cause Analysis (Outflow)
| Why 1 | Inner Diameter Undersize ( mix Up) |
| Why 2 | ID Checked in Sampling Basis |
| Why 3 | Due to less qty. not able to detect. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | RM Coil Change Initial Parts Mix-up |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 1.100% Inspection Started. 2. Training Provided to the Operators, Final Inspectors & Recorded | QA | 20/08/2023 | Completed | |
| Occurance | Procedure is Defined for Coil Change Parts Handling | QA & Production | 20/11/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% ID Check Point Added. |
| 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) |
WI And SOP Not Displayed for Coil Change Initial Parts Handling 516_Occurance_Before.pdf |
| Occurance (After) |
WI And SOP Displayed for Coil Change Initial Parts Handling 516_Occurance_After.pdf |
| Outflow (Before) |
Operator not aware. 516_Outflow_Before.pdf |
| Outflow (After) |
Training Given. 516_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Horizontal Deployment Done For KOPG. |
12. Document Review
| Documents | WISOP, InspCheckSheet |
| Specify Other Document | Training Record |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Reviewed 1000 found ok |