QFR No - 8000853857
Defect Details
| NC No. | 8000853857 |
| NC Date | 05/12/2023 |
| NC Submission Date | |
| Part No. | S2HT52107B |
| Part Name | OUTER SPRING K0PG |
| Supplier Name & Code | 101236-SUMA SPRINGS PRIVATE LIMITED |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | DIMN.U/SIZE.-ID LESS ISSUE |
1. Problem Description
| Defect Description | K0PG outer spring ID under size issue |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qc@sumasprings.com |
| Plant Head/CEO Email ID | vp@sumasprings.com |
| 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
|
0
|
0
|
1000
|
| Check Qty |
1000
|
0
|
0
|
0
|
0
|
1000
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Quality awareness created amongst team, Segregation at ETL end as well as Suma End |
3. Process Flow
| Process Flow Description |
|---|
| COILNG + TEMPERING1+GRINDING +SHOT PEENING+TEMPERING 2+SCRAGING+POWDER COATING+PDI+PACKING AND DESPATCH |
4. Process Details
| Process / Operation | COILING |
| Outsource | Yes |
| Machine / Cell | COILING CNC |
| Machine / Cell No. | SIMCO,SCM6100+HCS |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | End coil shift | Verified and found NG | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | IS2500-2K |
7. Root Cause Analysis (Occurance)
| Why 1 | ID under size |
| Why 2 | End coil shift |
| Why 3 | Setting part |
| Why 4 | During initial set up |
| Why 5 | |
| Root Cause (Occurance) | Setting part |
Root Cause Analysis (Outflow)
| Why 1 | ID under size |
| Why 2 | Stage random inspection |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Stage random inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Setting part will be scrapped and pit in red box before production | Grinding incharge | 08/12/2023 | 08/12/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | During grinding stage 100 % Visual inspection to verify the end coil shift |
| Inspection Method | Other |
| Other Inspection Method | VisualInspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | IS2500-2K |
10. Evidance of Countermeasure
| Occurance (Before) |
Setup part scrapped at the end of shift 608_Occurance_Before.docx |
| Occurance (After) |
Setup part scrapped immediately 608_Occurance_After.docx |
| Outflow (Before) |
Random inspection during grinding stage 608_Outflow_Before.pdf |
| Outflow (After) |
100 % visual inspection during grinding stage 608_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | F1GN101102B (MAIN SPRING) |
12. Document Review
| Documents | ControlPlan, ProcessFlowChart, InspCheckSheet |
| Specify Other Document | Q ALERT |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |