QFR No - 8000849150
Defect Details
| NC No. | 8000849150 |
| NC Date | 19/10/2023 |
| NC Submission Date | |
| Part No. | 53BJF00102 |
| Part Name | PISTON (Ø18) |
| Supplier Name & Code | 100177-SPECIALITY SINTERED PRODUCTS P |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | DIMETER UNDERSIZE-OD UNDERSIZE FOUND UPTO 17.904MM |
1. Problem Description
| Defect Description | Piston OD 17.923 ~ 17.943 mm Undersize found up to 17.904 mm |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 5 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | gh5t3exnukab30icfhh4ky1b.jpg |
Supplier Communication Details
| Quality Head Email ID | ganesh.padwalkar@specialitysintered.com |
| Plant Head/CEO Email ID | lalit.chaudhari@ssplpune.com |
| MD Email ID | lalit.chaudhari@ssplpune.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
30600
|
9000
|
0
|
9000
|
20000
|
68600
|
| Check Qty |
30600
|
9000
|
0
|
9000
|
20000
|
68600
|
| NG Qty |
12600
|
0
|
0
|
0
|
0
|
12600
|
| Scrap | 12600 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1) Warehouse :-For 20,000 no`s 100 % Checking Done By SSPL Representative , Transit :- NIl . 2) All FG material Hold and started 100 % OD inspection of parts By Ring Gauge started. |
3. Process Flow
| Process Flow Description |
|---|
| 1)Forming 2)Sintering ,3)Sizing, 3)Machining .5)Drilling.6)Pre dispatch Inspection .7)Packing & Dispatch. |
4. Process Details
| Process / Operation | Sizing |
| Outsource | No |
| Machine / Cell | 45s1 |
| Machine / Cell No. | 45S1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled Operator | Skilled Operator At Sizing Operation Verified Found Ok | O |
| Method | Incorrect Method Of Inspection | Verified Inspection Method As PerControl Plan Decided. Decided | O |
| Tool | Incorrect Tool | Verified Sizing Die Bottom Side Chamfer Height Excess | X |
| Material | Incorrect Raw Material | Verified Ok | O |
| Machine | Wrong Machine Used For Sizing Operation . | Verified Found Ok Correct Machine Used . | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 75 |
7. Root Cause Analysis (Occurance)
| Why 1 | Piston OD 17.923 ~ 17.943 mm Undersized found up to 17.904 mm |
| Why 2 | During The Sizing Process Part Getting Under Size |
| Why 3 | Sizing Die Bottom Side Chamfer Height Excess. |
| Why 4 | Die Bottom Side Chamfer Height Checkpoint Not Available In Tool Control Plan . |
| Why 5 | |
| Root Cause (Occurance) | Die Bottom Side Chamfer Height Checkpoint Not Available In Tool Control Plan . |
Root Cause Analysis (Outflow)
| Why 1 | Piston OD 17.923 ~ 17.943 mm Undersized found up to 17.904 mm |
| Why 2 | Defective part Pass from Final Inspection . |
| Why 3 | Not Detected In Final Inspection. |
| Why 4 | -Inspection Done As Per Sampling Plan . . |
| Why 5 | |
| Root Cause (Outflow) | -Inspection Done As Per Sampling Plan . . |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | On Job Training provided through Opl To inspectors . | Sunil Shejwal | 20/11/2023 | 20/10/2023 | Completed |
| Outflow | 100 % Inspection Started Till Permanent Action Implementation | Sunil Shejwal | 20/11/2023 | 20/10/2023 | Completed |
| Occurance | 1. Check Point Of Chamfer Height Checkpoint Added In Tool Control Plan . | Mr Mahesh Shinde | 25/10/2023 | 20/10/2023 | Completed |
| Outflow | Quality Alert displayed at final inspection and Sizing section | Sunil Shejwal | 22/11/2023 | 20/10/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No Change |
| 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) |
Check Point Not Available In Tool Control Plan 585_Occurance_Before.pdf |
| Occurance (After) |
Check Point Of Chamfer Height Checkpoint Added In Tool Control Plan . 585_Occurance_After.pdf |
| Outflow (Before) |
Sampling Inspection At Final Inspection . 585_Outflow_Before.pdf |
| Outflow (After) |
100 % Od Inspection Started Till Action Implementation . 585_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, InspCheckSheet |
| Specify Other Document | Opl |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |