QFR No - 8000842148
Defect Details
| NC No. | 8000842148 |
| NC Date | 26/08/2023 |
| NC Submission Date | |
| Part No. | F2GN25602B |
| Part Name | MAIN SPRING Ø33 SPD |
| Supplier Name & Code | 101225-HELICAL SPRINGS |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | LENGTH OVERSIZE-FREE LENGTH OVERSIZE OBS.375MM |
1. Problem Description
| Defect Description | Free length over size by 3 mm. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 229 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality.waluj@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 |
1500
|
0
|
0
|
800
|
1000
|
3300
|
| Check Qty |
1500
|
0
|
0
|
800
|
1000
|
3300
|
| NG Qty |
229
|
0
|
0
|
0
|
0
|
229
|
| Scrap | 229 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Problem Verified And Checked All Material in Stock. |
3. Process Flow
| Process Flow Description |
|---|
| Raw Material Receipt & Inspection, Coiling, Stress Relieving, End Grinding, Shot Peening, Scragging, Length & Wavyness checking, Strain-aging, Surface Finish- Oiling, Final Inspection/ PDI, Packing, Dispatch. |
4. Process Details
| Process / Operation | Satge Of Packing. |
| Outsource | No |
| Machine / Cell | NA |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Wrong Material Mix | Skill Matrix Found Ok | O |
| Tool | NA | Check Sheet Found Ok | O |
| Material | RMTC Found Ok | TC Verification | O |
| Method | Area Not Identified For New Developments Parts. | Stock sheet Verification | X |
| Machine | Herdon | Verified 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 | Length Oversize |
| Why 2 | Other Material Mixed With Ok Parts |
| Why 3 | Both Are The Similar Looking Items |
| Why 4 | Storing In Same Place |
| Why 5 | Due To No Route cards Available For NPD Parts. |
| Root Cause (Occurance) | No Identification (Route Card) Placed in NPD Parts. |
Root Cause Analysis (Outflow)
| Why 1 | Length Oversize |
| Why 2 | Not Detected During PDIR Due To Less Qty. |
| Why 3 | PDIR Done On Sampling Basis. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Sample Size Not Sufficient To Detect The Issue (Only 5 Nos for 1000) |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Route Cards Started For Development Parts. | Production | 30/08/2023 | Completed | |
| Outflow | Sampling Plan Increased For Next 3 Lots ( 20 Nos Per 1000Nos) | QA | 30/08/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Sampling Plan Increased. |
| 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) |
Route Cards Not Available For NPD Parts 535_Occurance_Before.pdf |
| Occurance (After) |
Route Card Available For NPD Parts 535_Occurance_After.pdf |
| Outflow (Before) |
Area Not Defined For NPD Parts. 535_Outflow_Before.pdf |
| Outflow (After) |
Area Defined and Training Given to Packing and Dispatch Station Employee. 535_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Similar Parts |
12. Document Review
| Documents | ProcessFlowChart, InspCheckSheet |
| Specify Other Document | Route Cards |
13. Effectiveness Of Action
| Reviewed Quantity | 10000 |
| Reason for submission | No any concern observed after action plan submitted. |