QFR No - 8000868409
Defect Details
| NC No. | 8000868409 |
| NC Date | 22/03/2024 |
| NC Submission Date | |
| Part No. | F2GN12502B |
| Part Name | MAIN SPRING J1A & J1D |
| Supplier Name & Code | 100180-BHALLA TECHTRAN INDUSTRIES LIM |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-PARELLELISM MORE |
1. Problem Description
| Defect Description | PARELLELISM MORE |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 91 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | sunilaggarwal.btl@gmail.com |
| Plant Head/CEO Email ID | plant1@btlsprings.com |
| MD Email ID | amitbhalla.btl@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
4500
|
4000
|
2000
|
0
|
12500
|
| Check Qty |
2000
|
4500
|
0
|
2000
|
0
|
8500
|
| NG Qty |
91
|
60
|
0
|
0
|
0
|
151
|
| Scrap | 0 |
| Rework | 151 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Check the all material lying at ETL end and warehouse as well as inhouse |
3. Process Flow
| Process Flow Description |
|---|
| RM Receipt & Inspection Coiling Stress relieving 1st End Grinding Shot Peening Stress relieving 2nd Scragging Final Inspection Packing & Dispatch |
4. Process Details
| Process / Operation | End Grinding |
| Outsource | No |
| Machine / Cell | CNC Grinding |
| Machine / Cell No. | WNJ Grinding m/c |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Wrong material grade used | Verify and found OK as per Drg. | O |
| Method | Grinding wheel dressing not as per decided freq. | Check wheel dressing record as per decided freq. | O |
| Tool | Grinding plate as per requirement | Found old grinding plate with hole size more | X |
| Man | New/Untrained operator | Verify operator skill matrix and found OK | O |
| Method | Grinding wheel alignment not ok | Check wheel alignment with block | O |
| Machine | Grinding feed more in programming | Verify and found OK | 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 | 05 Nos/Lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Parallelism out of specification |
| Why 2 | End grinding was in taper |
| Why 3 | More clearance in grinding plate hole w.r.t. spring OD |
| Why 4 | Old grinding plate used with hole size more |
| Why 5 | No identification on grinding plate |
| Root Cause (Occurance) | Old grinding plate with hole size more used during grinding operation due to no identification on grinding plates |
Root Cause Analysis (Outflow)
| Why 1 | Parallelism out of specification |
| Why 2 | Not detect during PDI |
| Why 3 | Sampling Inspection |
| Why 4 | As per decided freq. |
| Why 5 | |
| Root Cause (Outflow) | Defected parts not detect during PDI inspection due to sampling inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Identify the grinding plates with No. and monthly validation started | Rajesh Choudhary | 28/03/2024 | 28/03/2024 | Completed |
| Occurance | Grinding plate hole size check point added in setup approval and in process inspection check sheet and verified by Q.C. | Rajesh Choudhary | 27/03/2024 | 28/03/2024 | Completed |
| Occurance | Separate racks made for storage of grinding plates with proper identification | Saudagar Prasad | 28/03/2024 | 28/03/2024 | Completed |
| Outflow | Sampling freq. increased in PDI stage (05 nos from each crates in place of 05 nos/lot) | Rajesh Choudhary | 27/03/2024 | 28/03/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Checking freq. increased in PDI stage |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 Nos/Bin |
10. Evidance of Countermeasure
| Occurance (Before) |
Unidentified grinding plate 725_Occurance_Before.jpg |
| Occurance (After) |
OPL displayed and provide training to all concerned 725_Occurance_After.pdf |
| Outflow (Before) |
Less sampling freq. 725_Outflow_Before.xls |
| Outflow (After) |
Sampling freq. increased and revised control plan 725_Outflow_After.xls |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All main spring in grinding operation |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 240 |
| Reason for submission | Found ok |