QFR No - 8000866611
Defect Details
| NC No. | 8000866611 |
| NC Date | 12/03/2024 |
| NC Submission Date | |
| Part No. | F2FA19033M |
| Part Name | K0PG FORK PIPE MACHINED |
| Supplier Name & Code | 101109-TUBE INVESTMENTS OF INDIA LIMI |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | DIMN.U/SIZE.-DIM 3+0.1 MM DISTANCE NG |
1. Problem Description
| Defect Description | Dim 3+0.1 mm observed 2.80 mm (undersize) |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 300 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | anandms@tii.murugappa.com |
| Plant Head/CEO Email ID | girisha@tii.murugappa.com |
| MD Email ID | mukeshahuja@tii.murugappa.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
3000
|
0
|
0
|
1000
|
500
|
4500
|
| Check Qty |
3000
|
0
|
0
|
1000
|
500
|
4500
|
| NG Qty |
300
|
0
|
0
|
0
|
0
|
300
|
| Scrap | 300 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| material Checked 100 % for Defective Parameter with Identification Marking |
3. Process Flow
| Process Flow Description |
|---|
| Raw Inward Inspection - CNC Machining - Drilling Operation - Deburring Operation - Oiling - Final Inspection - PDIR - Dispatch. |
4. Process Details
| Process / Operation | CNC Machining |
| Outsource | No |
| Machine / Cell | cell No -6 |
| Machine / Cell No. | Cell No -6 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Raw Material ID Undersize | Verified Records & No Issue with Raw tube ID issue found | O |
| Man | operator Skill | Verified through Gemba observation and found Operator Skill with Minimum Level as per Matrix | X |
| Machine | More offset limit | Checked In Machine Parameter & found ware offset limit to 0.3 mm | X |
| Tool | Tool Damage | Verified through Simulation and found that ID mark/scoring mark generated | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | PDIR |
7. Root Cause Analysis (Occurance)
| Why 1 | Dim. 3+0.1 distance u/s found at customer end |
| Why 2 | ID Chamfer Length 1 mm observed 0.80 mm |
| Why 3 | Total ID Depth found shift in Z –axis in CNC machining |
| Why 4 | Excess offset of 0.2 mm given in Z-axis in CNC machining |
| Why 5 | Manual error in offset Input against 0.02 mm given 0.2 mm. |
| Root Cause (Occurance) | Simen based control CNC M/c ware offset Limit is 0.3 mm. |
Root Cause Analysis (Outflow)
| Why 1 | Dim. 3+0.1 distance u/s found at customer end |
| Why 2 | ID Chamfer Length 1 mm observed 0.80 mm |
| Why 3 | Total ID Depth found shift in Z –axis in CNC machining |
| Why 4 | Not detected during final inspection |
| Why 5 | Inspection done as per sampling plan |
| Root Cause (Outflow) | Inspection was done on sampling basis. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Point added in Hourly inspection for Inspection with Vernier for Dim 3 mm.& range Define for Vernier Inspection | MR. Abishak Yadav | 12/04/2024 | 12/04/2024 | Completed |
| Occurance | Discussed with Simen Controller Manufactures for reduced ware offset limit , denied to change , Training given to Supervisor & operators for offset giving & need to check part for 3 mm dim after every offset given in Z-axis. | Mr. Palak Shah | 13/04/2024 | 12/04/2024 | Completed |
| Outflow | Inspection Point added in Final Inspection for Visual Inspection with Master OK & NG Part Displayed at Inspection Table. | Mr. Abishek Yadav | 13/04/2024 | 12/04/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Visual Inspection at final Inspection with compare with OK & NG Part. |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
10. Evidance of Countermeasure
| Occurance (Before) |
Hourly inspection for Inspection with Vernier for Dim 3 mm.& NO range Define for Vernier Inspection 711_Occurance_Before.pptx |
| Occurance (After) |
Hourly inspection for Inspection with Vernier for Dim 3 mm.& range Define for Vernier Inspection 711_Occurance_After.pptx |
| Outflow (Before) |
No Inspection Point added in Final Inspection for Visual Inspection & No Defect Samples Displayed 711_Outflow_Before.pptx |
| Outflow (After) |
Inspection Point added in Final Inspection for Visual Inspection & Defect Samples Displayed 711_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | K86 -A |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | DIMN.U/SIZE.-DIM 3+0.1 MM DISTANCE NG. |