QFR No - 8000859440
Defect Details
| NC No. | 8000859440 |
| NC Date | 18/01/2024 |
| NC Submission Date | |
| Part No. | 520DW01303 |
| Part Name | FLANGE BOLT SUZUKI |
| Supplier Name & Code | 100073-SINGLA FORGING (P) LTD |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-THREAD NG/ OVERSIZE |
1. Problem Description
| Defect Description | Fitment issue - Thread NG |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 28 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@singlaforging.in |
| Plant Head/CEO Email ID | quality@singlaforging.in |
| MD Email ID | jain@singlaforging.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5028
|
0
|
0
|
0
|
0
|
5028
|
| Check Qty |
5028
|
0
|
0
|
0
|
0
|
5028
|
| NG Qty |
28
|
0
|
0
|
0
|
0
|
28
|
| Scrap | 28 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| segrsdmklxfd |
3. Process Flow
| Process Flow Description |
|---|
| 10 RM 20 FORGING 30 FACING & COLLAR MACHINING 40 ROLLING 50 H/T 60 SURFACE PLATING 70 FINAL INSPECTION 80 PACKING 90 DISPATCH |
4. Process Details
| Process / Operation | COLLAR MACHINING |
| Outsource | No |
| Machine / Cell | TURNING TRAUB MACHINING |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | TOOL FREQENCY RESHARPNING WAS NOT EFFECTIVE | TOOL LIFE RECVALIDATION DONE | X |
| Man | OPERATOR WAS SKILLED | SKILL MATRIX VERIFIED | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | VISUAL INSPECTION |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | THE PROBLEM OCCURED AT FACING & COLLAR MACHINING STAGE OF MANUFATURING SEQUENCE |
| Why 2 | THE FACING TOOL WAS WEAR RESULTED INTO BURR ON FACE |
| Why 3 | THE RESHARPNING FREQUENCY FOR THE CUTTING TOOL WAS DEFINED 200 NO`S |
| Why 4 | RESHARPNINING FREQWUENCY WAS NOT EFFECTIVE, NEED TO BE REVALIDATED AS RAISED CUSTOMER COMPLAINT |
| Why 5 | |
| Root Cause (Occurance) | RESHARPNINING FREQWUENCY WAS NOT EFFECTIVE, NEED TO BE REVALIDATED AS RAISED CUSTOMER COMPLAINT |
Root Cause Analysis (Outflow)
| Why 1 | VISUALLY INSPECTION WAS NOT EFFECTIVE |
| Why 2 | THOUGH INSPECTOR WAS SKILLED YET IF A FEW PARTS SKIPPED FROM VISUAL INSPECTION |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | THOUGH INSPECTOR WAS SKILLED YET IF A FEW PARTS SKIPPED FROM VISUAL INSPECTION |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | THOUGH INSPECTOR WAS SKILLED YET IF A FEW PARTS SKIPPED FROM VISUAL INSPECTION | Mr. RAM HARESH | 01/02/2024 | 12/02/2024 | Completed |
| Outflow | DEDICATED PERSON APPOINTED | Mr. AMBHORE | 08/02/2024 | 14/02/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | DEDICATED INSPECTOR DEPLOYED, SKILL MATRIX REVIEWED AFTER SHIFT OVER |
| Inspection Method | Other |
| Other Inspection Method | 100% VISUAL |
| Check Point at Final Inspection | No |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
EVIDANCE ATTACHED 637_Occurance_Before.xlsx |
| Occurance (After) |
EVIDANCE ATTACHED 637_Occurance_After.xlsx |
| Outflow (Before) |
EVIDANCE ATTACHED 637_Outflow_Before.jpeg |
| Outflow (After) |
EVIDANCE ATTACHED 637_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NO |
12. Document Review
| Documents | |
| Specify Other Document | OJT |
13. Effectiveness Of Action
| Reviewed Quantity | 352 |
| Reason for submission | Checked found ok |