QFR No - 8000862067
Defect Details
| NC No. | 8000862067 |
| NC Date | 07/02/2024 |
| NC Submission Date | |
| Part No. | 520DZ01712 |
| Part Name | FORK BOLT DF181085 |
| 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 | 150 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualityassurance@sangkaj.com |
| Plant Head/CEO Email ID | qualityassurance@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 |
250
|
0
|
0
|
200
|
0
|
450
|
| Check Qty |
250
|
0
|
0
|
200
|
0
|
450
|
| NG Qty |
150
|
0
|
0
|
200
|
0
|
350
|
| Scrap | 0 |
| Rework | 150 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % sorting at ETL end with special identification. Also 100% sorting done at M/s Sangkaj Steel End with special identification. |
3. Process Flow
| Process Flow Description |
|---|
| RM Store - RM Inspection - Traub - Pre roll dia Grinding -Tapping M10 - Thread Rolling M26 - Plating - Final inspection - Dispatch. |
4. Process Details
| Process / Operation | Thread Rolling |
| Outsource | No |
| Machine / Cell | Thread Rolling |
| Machine / Cell No. | Rolling - 02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Wrong tool used for operation. | Wrong tool used for operation. | O |
| Machine | Machine parameter not okay at Grinding stage . | Parameter observed at operation stage & found okay. | O |
| Machine | Machine parameter not okay at machining stage. | Parameter observed at operation stage & found okay. | O |
| Method | inspection method not okay | Less sampling frequency. | X |
| Man | Skipped from inspection. | NG part found at customer end. | X |
| Material | Wrong material used. | Verified the TC report & Found okay. | O |
| Machine | Machine parameter not okay at machining stage . | Parameter observed at operation stage & found okay. | O |
| Machine | Part dimn not as per drawing | Pre roll dimn observed at higher side. | X |
| Method | Loading & Unloading method not okay. | During Gemba visit at operation stage loading & unloading method observed okay. | O |
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 | M26 Threading not okay. |
| Why 2 | After plating threading not qualified in mating part. |
| Why 3 | On part minor dia found at higher side. |
| Why 4 | On part Pre roll dia observed at higher side |
| Why 5 | Operator is not aware about effect of parts makes at higher side of specification. |
| Root Cause (Occurance) | Operator is not aware about effect of parts makes at higher side of specification. |
Root Cause Analysis (Outflow)
| Why 1 | M26 Threading not okay. |
| Why 2 | Skipped from Inspection |
| Why 3 | defect not detect in during final inspection. |
| Why 4 | Less sampling frequency. |
| Why 5 | |
| Root Cause (Outflow) | Less sampling frequency. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Pre roll diameter to be maintain at lower side of specification. | Mr Raut. | 23/01/2024 | 23/01/2024 | Completed |
| Outflow | Sampling inspection frequency increase at final inspection from 05 nos to 50 nos. | Mrs Mukta | 23/01/2024 | 23/01/2024 | Completed |
| Occurance | Training & Awareness given to operator. | Mr Anil | 22/01/2024 | 22/01/2024 | 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. | Sampling |
| Sampling | No |
| Sample Size | 50 Nos |
10. Evidance of Countermeasure
| Occurance (Before) |
Operator is not aware about effect of parts makes at higher side of specification. 661_Occurance_Before.pdf |
| Occurance (After) |
Pre roll diameter to be maintain at lower side of specification. 661_Occurance_After.pdf |
| Outflow (Before) |
Less inspection sampling frequency on mating part. 661_Outflow_Before.pdf |
| Outflow (After) |
Sampling inspection frequency increase at final inspection from 05 nos to 50 nos 661_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applicable for all type of fork bolt |
12. Document Review
| Documents | ControlPlan, PFMEA, InspCheckSheet |
| Specify Other Document | N/A |
13. Effectiveness Of Action
| Reviewed Quantity | 596 |
| Reason for submission | Verified and found ok |