QFR No - 8000852795
Defect Details
| NC No. | 8000852795 |
| 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 | DIAMETER OVER SIZE-OD O/S & SCRTCH MARK ON OD |
1. Problem Description
| Defect Description | DIAMETER OVER SIZE-OD O/S & Taper & SCRTCH MARK ON OD - Shaft Maxima |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 514 |
| Is Defect Repeatative? | No |
| 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
|
1000
|
0
|
8000
|
| Check Qty |
4500
|
0
|
0
|
1000
|
0
|
5500
|
| NG Qty |
514
|
0
|
0
|
0
|
0
|
514
|
| Scrap | 0 |
| Rework | 514 |
| Under Deviation | 0 |
| Containment Action |
|---|
| segregate pipe line material at ETL end & inhouse. |
3. Process Flow
| Process Flow Description |
|---|
| BAR CUTTING- TURNING -STRAIGHTENING-GRINDING- FINAL INSPECTION-PACKING-DISPATCH |
4. Process Details
| Process / Operation | OD grinding |
| Outsource | No |
| Machine / Cell | Grinding m/c |
| Machine / Cell No. | 1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | OD gauge not available. | OD checked by micrometer as OD gauge given for calibration. | X |
| Machine | Grinding wheel wear out | Wheel Frequency not defined | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | DIAMETER OVER SIZE-OD O/S & SCRTCH MARK ON OD |
| Why 2 | Grinding wheel wear out |
| Why 3 | Grinding wheel dressing frequency not defined. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Grinding wheel dressing frequency not defined. |
Root Cause Analysis (Outflow)
| Why 1 | DIAMETER OVER SIZE-OD O/S & SCRTCH MARK ON OD |
| Why 2 | OD Not checked by Gauge |
| Why 3 | OD gauge given for calibration. |
| Why 4 | Gauge calibration was due. |
| Why 5 | |
| Root Cause (Outflow) | Gauge calibration was due. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | New OD Snap gauge purchased, OD 100 % Check by snap gauge. | Inspector | 25/11/2023 | 27/11/2023 | Completed |
| Occurance | Grinding wheel dressing frequency defined after | operator | 25/11/2023 | 27/11/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | OD check by snap gauge |
| 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) |
Grinding wheel dressing frequency not defined. 600_Occurance_Before.jpeg |
| Occurance (After) |
Grinding wheel dressing frequency defined . 600_Occurance_After.jpeg |
| Outflow (Before) |
OD checked by micrometer as OD gauge given for calibration. 600_Outflow_Before.jpeg |
| Outflow (After) |
New OD Snap gauge purchased, OD 100 % Check by snap gauge. 600_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Machine,Man |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | G.wheel dress.Record |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |