QFR No - 8000848504
Defect Details
| NC No. | 8000848504 |
| NC Date | 12/10/2023 |
| NC Submission Date | |
| Part No. | B2SG01026O |
| Part Name | PUSH ROD FORK FOR M/CYL 2WH,RE J1C |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | THREADING NOT OK-EXCESS THREADING |
1. Problem Description
| Defect Description | HREADING NOT OK-EXCESS THREADING |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 300 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@apw3.co.in |
| Plant Head/CEO Email ID | kurund.ma@sharp-engineers.com |
| MD Email ID | urkhandelwal@sharp-engineers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1100
|
0
|
0
|
500
|
500
|
2100
|
| Check Qty |
1100
|
0
|
0
|
500
|
500
|
2100
|
| NG Qty |
300
|
0
|
0
|
228
|
55
|
583
|
| Scrap | 583 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done immediately at ETL and in-house pipeline material |
3. Process Flow
| Process Flow Description |
|---|
| 10) RM Inward 20) RM Storage 30) Parting & Forming 40) Milling Operation 50) Drilling60) Taping (M8x1.25-6G)70) Drilling Operation 80) O.D. Grinding 90)Plating Process 100)Inward Inspection 110) Final Inspection 120)Pre-Dispatch Inspection 130) Packing & Forwarding |
4. Process Details
| Process / Operation | Drilling Operation |
| Outsource | No |
| Machine / Cell | SE/DR/03 |
| Machine / Cell No. | Machine Shop |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Un-skilled Operator | Stage wise skill matrix and operator license are not evident as per F/HR/06 | O |
| Method | Operator Working Method Wrong | SOP/WI available on machine and operator aware about it and being followed. | O |
| Tool | Excess Tap length | Tapping length was excess | X |
| Machine | Holding in the fixture with required pin gauge | SOP/WI available on machine and operator aware about it and being followed. | O |
| Material | Incorrect RM grade | Third part inspection verified for chemical composition and hardness testing as per requirement. | 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 | 1:1 |
7. Root Cause Analysis (Occurance)
| Why 1 | THREADING NOT OK-EXCESS THREADING |
| Why 2 | Excess Tap length observed. |
| Why 3 | Non-standard tap used |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Non-standard tap used |
Root Cause Analysis (Outflow)
| Why 1 | THREADING NOT OK-EXCESS THREADING |
| Why 2 | Inspector not aware about the defect |
| Why 3 | OPL not displayed at inspection stage |
| Why 4 | New defect phenomena |
| Why 5 | |
| Root Cause (Outflow) | Inspector not aware about the defect because of new defect phenomena. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Tap length standardized and sizes are being checked before start of the production. | Mr. Vinod Patil | 14/10/2023 | 20/10/2023 | Completed |
| Outflow | OPL displayed at final inspection stage and training given to inspector for awareness purpose. | Mr. Shaikh Laik | 12/10/2023 | 14/10/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | OPL displayed |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
Non-standard tap used 579_Occurance_Before.pptx |
| Occurance (After) |
Tap length standardized and sizes are being checked before start of the production. 579_Occurance_After.pptx |
| Outflow (Before) |
New defect phenomena 579_Outflow_Before.pptx |
| Outflow (After) |
OPL displayed at final inspection stage and training given to inspector for awareness purpose. 579_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | PUSH ROD FORK R121 (B3KC00702O) |
12. Document Review
| Documents | PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |