QFR No - 8000839779
Defect Details
| NC No. | 8000839779 |
| NC Date | 08/08/2023 |
| NC Submission Date | |
| Part No. | B2EH08502O |
| Part Name | END CONNECTOR MASTER SIDE NTORQ |
| Supplier Name & Code | 101221-SUNREN AUTOMOTIVE PRIVATE LIMI |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | OTHER-LUG NOT OK |
1. Problem Description
| Defect Description | LUG NOT OK |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 1359 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | shivank@sunren.in |
| Plant Head/CEO Email ID | dharmbir@sunren.in |
| MD Email ID | subhashsaini@sunren.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
0
|
17000
|
9000
|
2000
|
3000
|
31000
|
| Check Qty |
0
|
17000
|
9000
|
2000
|
3000
|
31000
|
| NG Qty |
0
|
243
|
0
|
0
|
0
|
243
|
| Scrap | 243 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% inspection will be carried out at warehouse and green dot marking is placed over the lug for ensurity. |
3. Process Flow
| Process Flow Description |
|---|
| Inspection of Raw Material - Cutting Multi Operation - Centerless Grinding - Milling - Cross Drill - Neck Drill-Cross Reamer - Pin Drill - Pin Assembly - Brazing - Facing1st - Facing-2nd -Chamfer- 100% Visual Inspection -Bending - Plating - Final Inspection - Packaging - Storage / Dispatch . |
4. Process Details
| Process / Operation | Bending |
| Outsource | No |
| Machine / Cell | Bending Fixture |
| Machine / Cell No. | 10 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Lack of Knowledge | Skill Matrix | O |
| Method | Inspection Method Not Effective | Gauge Verification | X |
| Tool | wear and tear of fixtures | Fixture Validation | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | wear & tear of bending fixture |
| Why 2 | Fixture was not hardened |
| Why 3 | Fixture life was not decided |
| Why 4 | Fixture not validated |
| Why 5 | Lack of awareness |
| Root Cause (Occurance) | Wear & Tear of bending fixture |
Root Cause Analysis (Outflow)
| Why 1 | Inspection process not effective |
| Why 2 | Checking Gauge found not effective |
| Why 3 | complete profile of the part was not covered in gauge |
| Why 4 | Gauge Design Needs improvement |
| Why 5 | Gauge Design not validated |
| Root Cause (Outflow) | Checking Gauge Found Not Effective. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Fixture will be replaced , Hardened , Gauge validation will be done and improvement will be done in bending fixture taking pin as a reference for bending. | Shivank | 29/09/2023 | 10/09/2023 | Completed |
| Outflow | Checking gauge will be re-designed considering pin shifting , part profile and pin angle. | Shivank | 29/09/2023 | 27/09/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Lug shift is checked 200% and green dot marking is started over the lug for ensurity. |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 5 |
10. Evidance of Countermeasure
| Occurance (Before) |
Fixture Gets Wear and Tear. 518_Occurance_Before.png |
| Occurance (After) |
New Bending Fixture Implemented. 518_Occurance_After.png |
| Outflow (Before) |
Only Pin was guided as a reference in the block. 518_Outflow_Before.jpg |
| Outflow (After) |
New Checking Fixture Made w.r.t Pin angle , pin shifting , part profile and connector angle concept. 518_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Presently Only single model is there. |
12. Document Review
| Documents | |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 300 |
| Reason for submission | Lug ok observed in corrected lot |