QFR No - 8000849095
Defect Details
| NC No. | 8000849095 |
| NC Date | 19/10/2023 |
| NC Submission Date | |
| Part No. | 550LG06702 |
| Part Name | SEAT PIPE-(HMS-30 & HMP-30) |
| Supplier Name & Code | 100929-HARSHAD ENGINEERING COMPANY |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | RUN OUT MORE-OD GREEOVE RUNOUT FOUND UPTO 1.49 MM |
1. Problem Description
| Defect Description | Hex OD Runout 1.49 mm found against 0.5 mm with respect to thread |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 2 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | gh5t3exnukab30icfhh4ky1b.jpg |
Supplier Communication Details
| Quality Head Email ID | qaharshad@miteshauto.com |
| Plant Head/CEO Email ID | sjkadam@miteshauto.com |
| MD Email ID | auto.mitesh@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
8000
|
6000
|
4000
|
5000
|
3500
|
26500
|
| Check Qty |
8000
|
6000
|
4000
|
5000
|
3500
|
26500
|
| NG Qty |
2
|
0
|
0
|
1
|
0
|
3
|
| Scrap | 3 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % sorting done for ETL End, HEC WIP & FG material with identification/star mark on each box |
3. Process Flow
| Process Flow Description |
|---|
| Cutting-Draw-Head Formation-Rough Grinding-CNC (Head, Boring & Tapping)-Punching-Finish Grinding-Final Inspection-Packing-Dispatch |
4. Process Details
| Process / Operation | Tapping |
| Outsource | No |
| Machine / Cell | Tapping machine |
| Machine / Cell No. | 161 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Drilling Spindle TR Bad Found upto | Found upto 0.07 mm, spec. 0.05 mm | X |
| Machine | Collet TR wrt Tapping Spindle not ok | Found upto 0.03 against 0.05 mm | O |
| Machine | Face cutter TR Bad | Found ok within 0.02 against 0.05 mm | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | As IS 2500 |
7. Root Cause Analysis (Occurance)
| Why 1 | Groove Runout wrt Threading found Excess |
| Why 2 | Threading Conc. wrt shank Dia. excess |
| Why 3 | Bore Conc. wrt OD excess |
| Why 4 | Boring/Drilling Spindle alignment found 0.07 to 0.08 against 0.05 mm. |
| Why 5 | Boring Spindle alignment disturb |
| Root Cause (Occurance) | Boring Spindle alignment disturb |
Root Cause Analysis (Outflow)
| Why 1 | Groove Runout wrt Threading found Oversize |
| Why 2 | Skipped From Final inspection |
| Why 3 | Sampling Insp. plan followed |
| Why 4 | Not detect while inspection |
| Why 5 | |
| Root Cause (Outflow) | Not detect while sampling inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Drilling Spindle TR wrt Collet checking freq. decided on weekly Basis | DDJ | 02/11/2023 | Completed | |
| Occurance | Drilling Spindle TR set within 0.03 mm | D.D. Jopale | 30/10/2023 | 31/10/2023 | Completed |
| Outflow | Collet Wise Runout check as per in-process insp. freq. | QA Inspector | 02/11/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NA |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | IS2500 |
10. Evidance of Countermeasure
| Occurance (Before) |
Drilling Spindle alignment disturb 586_Occurance_Before.pdf |
| Occurance (After) |
Drilling Spindle TR set within 30 Microns by using dial gauge, Weekly Spindle TR checking Freq. decided 586_Occurance_After.pdf |
| Outflow (Before) |
Parts check by using lever dial gauge as per sampling freq. 586_Outflow_Before.pdf |
| Outflow (After) |
Gauge Made to check bore conc. wrt shank & Runout checked collet-wise as per In-process Insp. freq. daily basis. 586_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | CNC, CS & SPM |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 10 |
| Reason for submission | ok |