QFR No - 8000862066
Defect Details
| NC No. | 8000862066 |
| NC Date | 07/02/2024 |
| NC Submission Date | |
| Part No. | 550DZ04702 |
| Part Name | FORK BOLT -UG4.5 |
| Supplier Name & Code | 100189-SANGKAJ STEEL PVT LTD. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-M26 THREAD FITMENT ISSUE |
1. Problem Description
| Defect Description | M26 Thread fitment NG |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 161 |
| 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 |
3000
|
0
|
0
|
500
|
0
|
3500
|
| Check Qty |
3000
|
0
|
0
|
500
|
0
|
3500
|
| NG Qty |
168
|
0
|
0
|
15
|
0
|
183
|
| Scrap | 0 |
| Rework | 183 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Sorting done at ETL End & M/s Sangkaj steel end. |
3. Process Flow
| Process Flow Description |
|---|
| RM - RM inspection - Wire Drawing - cold forging - cold forging inward - CNC operation - Thread rolling - Plating - Final inspection - Dispatch. |
4. Process Details
| Process / Operation | Thread Rolling |
| Outsource | No |
| Machine / Cell | Thread rolling |
| Machine / Cell No. | TRG Rolling. |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Skipped from inspection. | NG part found at customer end, | X |
| Machine | Less Or more feed mark speed. | Verified the machine parameter & found okay. | O |
| Method | Loading & Unloading method not okay at Thread rolling stage. | Gemba visit at rolling operation stage & found okay. | O |
| Machine | Less or more RPM | Verified the machine parameter & found okay. | O |
| Method | Loading & unloading method not okay at CNC operation. | Gemba visit at CNC operation stage & found okay. | O |
| Tool | Thread roll not okay | Verified the thread roll & thread roll not as per standard. | X |
| Material | Wrong material used. | verified the material TC & found okay. | O |
| Man | Unskilled operator | Verified the skill matrix at operation stage & found okay, | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | On mating part |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 -10nos |
7. Root Cause Analysis (Occurance)
| Why 1 | NOT AS PER SPECIFICATION-M26 THREAD FITMENT ISSUE |
| Why 2 | M26 Thread observed damage mark. |
| Why 3 | Rolling impression mark found on part. |
| Why 4 | Thread roll damage. |
| Why 5 | less thread rolling frequency. |
| Root Cause (Occurance) | less thread rolling frequency. |
Root Cause Analysis (Outflow)
| Why 1 | Skipped from inspection. |
| Why 2 | NG part not detect at final inspection. |
| Why 3 | Inspection done on sampling basis with mating part. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspection done on sampling basis with mating part. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| 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%. | Mrs Mukta | 22/01/2024 | 22/01/2024 | Completed |
| Occurance | Frequency increase on thread roll . | Mr Raut. | 01/02/2024 | 01/02/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | N/A |
| Inspection Method | Other |
| Other Inspection Method | Mating part |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Thread rolling frequency is less i.e 50000 nos 660_Occurance_Before.pptx |
| Occurance (After) |
Thread rolling frequency is increase from 50000 nos to 40000 nos. 660_Occurance_After.pptx |
| Outflow (Before) |
Less inspection frequency. 660_Outflow_Before.pptx |
| 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%.. 660_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applicable for all type of fork bolt. |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, PFMEA, InspCheckSheet |
| Specify Other Document | N/A |
13. Effectiveness Of Action
| Reviewed Quantity | 364 |
| Reason for submission | Verified and found ok |