QFR No - 8000862164
Defect Details
| NC No. | 8000862164 |
| NC Date | 07/02/2024 |
| NC Submission Date | |
| Part No. | 520DZ00212 |
| Part Name | FORK BOLT K60-(DS181012) |
| Supplier Name & Code | 101263-SINGLA PRECISION SCREWS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-M10 THREAD GO NOT QUALIFYING & NOGO QUAL |
1. Problem Description
| Defect Description | M10 THREAD GO NOT QUALIFYING & NOGO QUALIFYING |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 10 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@singlaprecision.com |
| Plant Head/CEO Email ID | quality@singlaprecision.com |
| MD Email ID | aditya@singlaprecision.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
800
|
0
|
0
|
0
|
0
|
800
|
| Check Qty |
800
|
0
|
0
|
0
|
0
|
800
|
| NG Qty |
28
|
0
|
0
|
0
|
0
|
28
|
| Scrap | 28 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Stock Check 100% at our end |
3. Process Flow
| Process Flow Description |
|---|
| Forging ,CNC-IST, CNC-2ND, BUFFING ,ROLLING ,SURFACE ,TREATMENT, FINAL INSPECTION -PACKING |
4. Process Details
| Process / Operation | CNC IST |
| Outsource | No |
| Machine / Cell | 01 |
| Machine / Cell No. | 02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | RM GRADE AND SIZE NOT OK | VALIDATED AND FOUND OK | O |
| Method | INSPECTION METHOD NOT EFFECTIVE | INSPECTION DONE AS PER SAMPLING PLAN SO PART SKIPPED FROM INSPECTION | X |
| Tool | TOOL WEAROUT | VALIDATED AND FOUND OK | O |
| Man | UNWAWARENESS OF OPERATOR | VALIDATED AND FOUND OPERATOR WAS LOW LEVEL | X |
| Machine | WORNG OFFSET | OFFSET NOT INTERLOCK | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 50 |
7. Root Cause Analysis (Occurance)
| Why 1 | M10 thread fitment NG (not qualifying to minor diameter pin 8.647, qualifying minor diameter pin 8.912 -) |
| Why 2 | Part minor dia over size because operator wrong offset give to machine |
| Why 3 | because offset not interlock |
| Why 4 | CNC Machine Programming did not set how much offset the operator could give only for |
| Why 5 | Machine checking Manor dia PPG gauge not 100% checked |
| Root Cause (Occurance) | Part minor dia over size because operator wrong offset give to machine |
Root Cause Analysis (Outflow)
| Why 1 | M10 thread fitment NG (not qualifying to minor diameter pin 8.647, qualifying minor diameter pin 8.912 -) |
| Why 2 | The Problem occurred at checking method |
| Why 3 | Final inspection only part checked as per sampling plan |
| Why 4 | operator part 100% not checked for ppg |
| Why 5 | |
| Root Cause (Outflow) | INSPECTION DONE AS PER SAMPLING PLAN SO PART SKIPPED FROM INSPECTION |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | MACHINE OFFSET INTERLOCK | ANIL | 09/03/2024 | 09/03/2024 | Completed |
| Outflow | CHECKING FREQ CHANGE 100 % CHECKING FINAL INSPECTION UPDATE | GANESH MAURYA | 09/03/2024 | 09/03/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection frequency change to 100% |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | no |
10. Evidance of Countermeasure
| Occurance (Before) |
OFFSET NOT INTERLOCK 663_Occurance_Before.xlsx |
| Occurance (After) |
OFFSET INTERLOCK 663_Occurance_After.png |
| Outflow (Before) |
CHECKING FREQ NOT CHANGE AS PER SAMPLING PLAN 663_Outflow_Before.png |
| Outflow (After) |
CHECKING FREQ CHANGE 100 % CHECKING FINAL INSPECTION UPDATE 663_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | CNC MACHINE |
12. Document Review
| Documents | ControlPlan, PokayokeCheckSheet, InspCheckSheet |
| Specify Other Document | POKA YOKA & CP |
13. Effectiveness Of Action
| Reviewed Quantity | 150 |
| Reason for submission | 8. Countermeasure ( Occurrence , Outflow & System side Actions ) - NOT UPDATED |