QFR No - 8000862174
Defect Details
| NC No. | 8000862174 |
| NC Date | 07/02/2024 |
| NC Submission Date | |
| Part No. | F2LY00312B |
| Part Name | SOCKET HEADED BOLT M8 - PRECOTE |
| Supplier Name & Code | 100926-BG FASTENING AND ENGINEERING I |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-LENGTH UNDERSIZE BY 5.0MM |
1. Problem Description
| Defect Description | LENGTH UNDERSIZE BY 5.0MM (other model mix-up) |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 428 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | waral.pavan@fontanagruppo.com |
| Plant Head/CEO Email ID | kulkarni.ph@fontanagruppo.com |
| MD Email ID | bose.shamik@fontanagruppo.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
15000
|
0
|
0
|
5000
|
0
|
20000
|
| Check Qty |
15000
|
0
|
0
|
5000
|
0
|
20000
|
| NG Qty |
428
|
0
|
0
|
0
|
0
|
428
|
| Scrap | 428 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% sorting at all location at customer end as well as at BGF end. |
3. Process Flow
| Process Flow Description |
|---|
| Cold forging / thread rolling / heat treatment / plating / pre-coating / final inspection |
4. Process Details
| Process / Operation | Forging / Rolling / HT / Plating / precoat / FI |
| Outsource | No |
| Machine / Cell | Forging / rolling / HT / Plating / precoat /fi |
| Machine / Cell No. | CC-119 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | na | na | X |
| Material | na | na | X |
| Machine | na | na | X |
| Tool | na | na | X |
| Method | Identification missing | Route card missing in material bin | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Sampling inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 nos/bin |
7. Root Cause Analysis (Occurance)
| Why 1 | Length undersize and ok part processed in same barrel of plating |
| Why 2 | Length undersize and ok part material bin kept near to each other, hence looking similar processed in same barrel in plating process |
| Why 3 | Length undersize part kept for plating rework but without identification tag |
| Why 4 | As multiple bin available for plating but route card kept over top bin only, and other bins stacking below the top bin, hence wrong part processed in mixed condition. |
| Why 5 | Identification tag missing in the bins except top bins with stacking layers of 4 bins. |
| Root Cause (Occurance) | Identification tag missing in the material bins stacking below the top bins (Total bins stacking 4 nos) |
Root Cause Analysis (Outflow)
| Why 1 | Length undersize part observed at customer end. |
| Why 2 | Length undersize part not detected during inspection |
| Why 3 | Less sampling size of 5 nos per lot |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Less sampling size at final inspection ( 5 nos only per lot) |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Identification tag will be provided to each bin stacking in layers | Mr. Dheeraj Singh | 08/02/2024 | 08/02/2024 | Completed |
| Outflow | 5 Nos sampling from each bin of material | Mr. Sharma Kuldeep | 07/02/2024 | 07/02/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Sampling size increased from 5 nos per lot to 5 nos from each bin |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 nos /bin |
10. Evidance of Countermeasure
| Occurance (Before) |
Identification tag over top bin only for part number 670_Occurance_Before.pdf |
| Occurance (After) |
Each bin of material identified with identification tag for part number 670_Occurance_After.pdf |
| Outflow (Before) |
Sampling inspection for 5 nos for lot 670_Outflow_Before.pdf |
| Outflow (After) |
Sampling inspection note added in pdi to check 5 nos samples for each bin of material 670_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | BGF |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | Route card check she |
13. Effectiveness Of Action
| Reviewed Quantity | 1164 |
| Reason for submission | Found ok |