QFR No - 8000852794
Defect Details
| NC No. | 8000852794 |
| NC Date | 24/11/2023 |
| NC Submission Date | |
| Part No. | D3AD00500M |
| Part Name | SHAFT CUT LENGTH (R122C MAXIMA Z) |
| Supplier Name & Code | 101222-SANGKAJ ENGINEERING PVT LTD- U |
| ETL Plant | 1152-ETL L-6/3/1DrivShaft |
| Defect Details | LENGTH OVERSIZE-LENGTH O/S BY 1 TO 2MM |
1. Problem Description
| Defect Description | Total Length Oversize by 1 to 2mm |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 1000 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | irfan@sangkaj.com |
| Plant Head/CEO Email ID | steel@sangkaj.com |
| MD Email ID | anirudh.2007@hotmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
7000
|
0
|
0
|
800
|
0
|
7800
|
| Check Qty |
1005
|
0
|
0
|
10
|
0
|
1015
|
| NG Qty |
1000
|
0
|
0
|
10
|
0
|
1010
|
| Scrap | 0 |
| Rework | 1000 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation Pipeline material at ETL end & pipeline In-house material. |
3. Process Flow
| Process Flow Description |
|---|
| Bar cutting- -Straightening -Grinding-final inspection- Packing -Dispatch |
4. Process Details
| Process / Operation | Bar cutting |
| Outsource | No |
| Machine / Cell | Troub M/c |
| Machine / Cell No. | 1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10 Nos per |
7. Root Cause Analysis (Occurance)
| Why 1 | LENGTH OVERSIZE-LENGTH O/S BY 1 TO 2 MM |
| Why 2 | Bar End pics mix-up in OK qty |
| Why 3 | Bar End pics Area not defined |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Bar End pics Area not defined. |
Root Cause Analysis (Outflow)
| Why 1 | LENGTH OVERSIZE-LENGTH O/S BY 1 TO 2 MM |
| Why 2 | T.L Oversize not detect in Final inspection . |
| Why 3 | Total Length Check as Sampling basis as per standard. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Total Length Check as Sampling basis as per standard. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | T.L C type Snap gauge provided to M/C&final inspection. T.L 100% check by C type Snap gauge | Operator /inspector | 04/12/2023 | 04/12/2023 | Completed |
| Occurance | Bar End Pics Area defined. | QA inspector | 29/11/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | T.L C type Snap gauge provided to M/C . T.L 100% check by C type Snap gauge. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
10. Evidance of Countermeasure
| Occurance (Before) |
Bar End pics Area not defined 599_Occurance_Before.jpeg |
| Occurance (After) |
Bar End pics Area defined 599_Occurance_After.jpeg |
| Outflow (Before) |
Total Length Check as Sampling basis as per standard by H.G. 599_Outflow_Before.jpeg |
| Outflow (After) |
T.L C type Snap gauge provided to final inspection. T.L 100% check by C type Snap gauge. 599_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Man & Method |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |