QFR No - 8000862175
Defect Details
| NC No. | 8000862175 |
| NC Date | 07/02/2024 |
| NC Submission Date | |
| Part No. | 520PC03307 |
| Part Name | UNDER BKT SUB-ASSY. K3 |
| Supplier Name & Code | 100061-BAJAJSONS LIMITED |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | OPERATION MISSING-M16 OPERAION MISSING |
1. Problem Description
| Defect Description | OPERATION MISSING-M16 OPERAION MISSING |
| Detection Stage | Customer End |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | pushpendra.singh@bajajsons.com |
| Plant Head/CEO Email ID | crbansal@bajajsons.com |
| MD Email ID | sanjay.bajaj@bajajsons.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
50
|
800
|
100
|
100
|
200
|
1250
|
| Check Qty |
50
|
300
|
0
|
100
|
200
|
650
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 0 |
| Rework | 1 |
| Under Deviation | 0 |
| Containment Action |
|---|
| No material at customer end .Inspection started in warehouse & checked 300 pcs. Out of 800 pcs. and found all material ok ,Rest 500+100pcs(Transit) will be checked before Dispatch to ETL as per their requirement. At our end we checked our F.G Stock and WIP material (Qty. 100+200) and found ok. |
3. Process Flow
| Process Flow Description |
|---|
| PRESS FITTING, MIG WELDING ,COUNTER SIDE BORES(TOP) , COUNTER SIDE BORES(BOTTOM SIDE) ,SLITTING(LEFT SIDE) , SLITTING(RIGHT SIDE) BROACHING(CHAMFER AT SLITTING )(LEFT AND RIGHT SIDE) , COUNTERING AT HOLE DIA.10.50(LEFT & RIGHT) , COUNTERING AT HOLE DIA. 8.60(LEFT & RIGHT) , DEBURRING AT MACHINE AREA , CARBON CLEANING-BORE OPENING , 2-TAPPING M6X1-6H , TAPPING M10 X 1.5 -6H(LEFT SIDE) , TAPPING M10 X 1.5 -6H(RIGHT SIDE) , 2-TAPPING 2-M6 X 1-6H , BUSH TAPPING M16 X 1.5-6H , STRAIGHTENING (PARALLISM INSPECTION) , DIE PASS OUT TO REMOVE THE DENT AND PHASPHATING SLIDGE (M30X1P-6H) , FINAL INSPECTION , PRE- DISPATCH INSPECTION PACKING &DISPATCH. |
4. Process Details
| Process / Operation | BUSH TAPPING M16X 1.5-6H |
| Outsource | No |
| Machine / Cell | TMS |
| Machine / Cell No. | 03 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Machine not working during tapping process | During verification found that machine is ok (No breakdown) | O |
| Method | Multiple part taking from trolley for tapping & kept at machine table | During verification found that operator is taking more then one part during tapping at table | X |
| Man | Unskilled manpower | Skilled manpower deployed at inspection | O |
| Tool | Worn out tap used & due to tapping not performed | Tap was ok because tap life monitoring | O |
| Method | Part skipped from tapping machine(Moved from previous operation to next operation) | During verification found that complete trolley moved to next stage | O |
| Method | Improper handling of NG part during final inspection | During verification found that checker was did not mark on NG part during inspection | X |
| Material | Hardness more in part | During verification found bush material was ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | Tapping miss of M16x1.5 part skipped |
| Why 2 | Tapping not performed due to part not loaded at machine |
| Why 3 | Due to mix-up of tapping done & without tapping parts |
| Why 4 | Mix-up due to multi parts taken from trolley & kept of machine table |
| Why 5 | Neglegency of machine operator |
| Root Cause (Occurance) | Mix-up due to multi parts taken from trolley & kept of machine table, resulting NG part mix up & reached at next stage |
Root Cause Analysis (Outflow)
| Why 1 | NG part skipped from final inspection & reached at customer end |
| Why 2 | NG part mix-up in ok material |
| Why 3 | Mix-up in ok material due to no marking on NG part |
| Why 4 | No marking on NG part due to negligency of checker |
| Why 5 | |
| Root Cause (Outflow) | No marking on NG part due to negligency of checker |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Awareness given to checkers for NG part handling | Irfan Ahmed | 16/02/2024 | 15/02/2024 | Completed |
| Occurance | OPL made & awareness given to machine operators for single part movement from trolley to avoid mix-up | Jasbir Singh | 15/02/2024 | 15/02/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | N/A |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 5 |
10. Evidance of Countermeasure
| Occurance (Before) |
Mix-up due to multi parts taken from trolley & kept of machine table 671_Occurance_Before.jpg |
| Occurance (After) |
Single part pick up from trolly for Bush Tapping M16X1.5. 671_Occurance_After.jpg |
| Outflow (Before) |
No marking on NG part due to negligency of checker 671_Outflow_Before.jpg |
| Outflow (After) |
Rework part move after marking as a decided place. 671_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | TMS -03/AVENGER & K-17 B/D/BSL U-III. |
12. Document Review
| Documents | PFMEA, WISOP |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 255 |
| Reason for submission | Checked and found ok |