QFR No - 8000851792
Defect Details
| NC No. | 8000851792 |
| NC Date | 10/11/2023 |
| NC Submission Date | |
| Part No. | 520HL00102 |
| Part Name | OIL LOCK COLLAR K60 |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-TOTAL LENGTH UNDERSIZE |
1. Problem Description
| Defect Description | Total Length undersize |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 8 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@mahavir.in.co.in |
| Plant Head/CEO Email ID | planthead@mahavirind.co.in |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
0
|
0
|
1200
|
0
|
2200
|
| Check Qty |
1000
|
0
|
0
|
1200
|
0
|
2200
|
| NG Qty |
8
|
0
|
0
|
0
|
0
|
8
|
| Scrap | 8 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All suspected finish good material segregation at customer end |
3. Process Flow
| Process Flow Description |
|---|
| Raw material Inward - store - Traub ( Final Length+ ID Chamfer+ OD Groove)- Back Side Chamfer - Cross Drilling - Inward Inspection- OD Grinding - Zinc Plating- Final Inspection - Packing - Dispatch |
4. Process Details
| Process / Operation | Traub -Final Length |
| Outsource | Yes |
| Machine / Cell | Traub Machine-03 |
| Machine / Cell No. | Traub Section |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Bend Pipe /Job Pusher Not Proper Working | Weight balance Not Sufficient for Bend Pipe Push | 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 | TOTAL LENGTH UNDERSIZE |
| Why 2 | Parting Pipe not Rest to as per Required Length job stopper. |
| Why 3 | Parting Pipe Not Push By Pusher Due to Weight balancer Weight Low . |
| Why 4 | Weight Balancer Not Sufficient For Bend Pipe Push. |
| Why 5 | |
| Root Cause (Occurance) | Weight Balancer Not Sufficient For Bend Pipe Push. |
Root Cause Analysis (Outflow)
| Why 1 | TOTAL LENGTH UNDERSIZE |
| Why 2 | During Final Inspection Length Under Size Part Not Deduct |
| Why 3 | Sampling Frequency Low |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Sampling Frequency Low |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Weight Balancer Not Sufficient For Bend Pipe Push. | Mr. Pralhad Bhawar | 13/11/2023 | 14/11/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% at Final stage and Ghoda gauge Provide On Traub Machine . |
| 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) |
Weight Balancer Not Sufficient before Weight Was 4 Kg 597_Occurance_Before.pptx |
| Occurance (After) |
Weight Balancer Weight Increase -Now 6Kg For Regular Pipe Or Bend Pipe Pushing Purpose. 597_Occurance_After.pptx |
| Outflow (Before) |
Ghoda Gauge Not Available On Traub Machine . 597_Outflow_Before.pptx |
| Outflow (After) |
Ghoda Gauge Provide On Traub Machine. 597_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Oil Lock Coller |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |