QFR No - 8000858053
Defect Details
| NC No. | 8000858053 |
| NC Date | 08/01/2024 |
| NC Submission Date | |
| Part No. | 550DZ03302 |
| Part Name | FORK BOLT |
| Supplier Name & Code | 100189-SANGKAJ STEEL PVT LTD. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-M10 THREAD LENGTH UNDERSIZE OBSERVED VAL |
1. Problem Description
| Defect Description | M10 thread length undersize |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 1360 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualityassurance@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 |
0
|
0
|
0
|
1000
|
0
|
1000
|
| Check Qty |
0
|
0
|
0
|
1000
|
0
|
1000
|
| NG Qty |
0
|
0
|
0
|
7
|
0
|
7
|
| Scrap | 0 |
| Rework | 7 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % sorting done at M/s Sangkaj steel end |
3. Process Flow
| Process Flow Description |
|---|
| RM store - RM inspection - Traub - CNC 1st - CNC 2nd - Thread rolling -plating - Final inspection -Dispatch. |
4. Process Details
| Process / Operation | Tapping Operation |
| Outsource | No |
| Machine / Cell | Tapping machine |
| Machine / Cell No. | Tapping machine |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Coolant Flow is not Proper | Less Coolant flow on Tap | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 Nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Thread Plug Gauge not Qualify in threading M10X1.25-6H |
| Why 2 | Small Burr stuck in Threading & settled at the bottom thread after Plating. |
| Why 3 | During tapping Small burr not get removed |
| Why 4 | Less Coolant Flow on tap. |
| Why 5 | |
| Root Cause (Occurance) | Less Coolant Flow |
Root Cause Analysis (Outflow)
| Why 1 | Thread Plug Gauge not Qualify in threading M10X1.25-6H |
| Why 2 | Defective parts get Skipped from Inspection |
| Why 3 | parts Checkied on Sampling Basis. |
| Why 4 | Inadequate Inspection Method |
| Why 5 | |
| Root Cause (Outflow) | Inspection Method inadequate |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Coolant Flow Increased during Tapping. Also Operator given training about not to do tapping if Coolant Flow is not Proper. | Mr. Pathan K.H. | 22/01/2024 | 22/01/2024 | Completed |
| Outflow | Inspection done on Sampling Basis, But the Sample Size Increased. Previously only 05 Nos were Checked for thread during Final Inspection, now Sample Size increased to 30%. | Mr Mukta | 23/01/2024 | 23/01/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection done on Sampling Basis, But the Sample Size Increased. Previously only 05 Nos were Checked for thread during Final Inspection, now Sample Size increased to 30%. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 30% |
10. Evidance of Countermeasure
| Occurance (Before) |
coolant direction is wrong. 630_Occurance_Before.pdf |
| Occurance (After) |
Correct the coolant direction & coolant is on tap. 630_Occurance_After.pdf |
| Outflow (Before) |
Inadequate Inspection Method 630_Outflow_Before.pdf |
| Outflow (After) |
Inspection done on Sampling Basis, But the Sample Size Increased. Previously only 05 Nos were Checked for thread during Final Inspection, now Sample Size increased to 30%. 630_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applicable for all fork bolt. |
12. Document Review
| Documents | ControlPlan, PFMEA, InspCheckSheet |
| Specify Other Document | N/A |
13. Effectiveness Of Action
| Reviewed Quantity | 184 |
| Reason for submission | Verified and found ok |