QFR No - 8000870319
Defect Details
| NC No. | 8000870319 |
| NC Date | 05/04/2024 |
| NC Submission Date | |
| Part No. | 550LG06702 |
| Part Name | SEAT PIPE-(HMS-30 & HMP-30) |
| Supplier Name & Code | 100929-HARSHAD ENGINEERING COMPANY |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | THREADING NOT OK-HALF THREAD |
1. Problem Description
| Defect Description | SEAT PIPE M8 X 1.25 -6G HALF THREAD FOUND AGAINST 14 MIN. REQUIRED |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | 3msmklh13r5mlf2ikgv3wqbt.jpg |
Supplier Communication Details
| Quality Head Email ID | qaharshad@miteshauto.com |
| Plant Head/CEO Email ID | sjkadam@miteshauto.com |
| MD Email ID | auto.mitesh@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
4100
|
0
|
0
|
7100
|
4250
|
15450
|
| Check Qty |
4100
|
0
|
0
|
7100
|
4250
|
15450
|
| NG Qty |
4
|
0
|
0
|
0
|
0
|
4
|
| Scrap | 4 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % sorting done for ETL End, HEC WIP & FG material |
3. Process Flow
| Process Flow Description |
|---|
| Cutting-Draw-Forging(Head Formation)-Rough Grinding-CNC (Head, Boring & Tapping)-Punching-Finish Grinding-Final Inspection-Packing-Dispatch |
4. Process Details
| Process / Operation | Tapping |
| Outsource | No |
| Machine / Cell | Tapping |
| Machine / Cell No. | SPM2 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | NA | NA | X |
| Machine | Limit switch malfunction | Observed Limit switch Malfunction | O |
| Man | NA | NA | X |
| Method | NA | NA | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | IS2500 |
7. Root Cause Analysis (Occurance)
| Why 1 | Tap not perform for complete threading length |
| Why 2 | Tap not insert/Pass up to full length |
| Why 3 | Tapping unit not work up to decided 15.0mm length |
| Why 4 | At tapping operation station limit switch malfunction happen |
| Why 5 | Limit switch malfunction happen |
| Root Cause (Occurance) | Limit switch malfunction happen |
Root Cause Analysis (Outflow)
| Why 1 | Half Threading |
| Why 2 | after tapping operation parts are checked on sampling basis |
| Why 3 | From initial stage it is carried out |
| Why 4 | Skip from Final Inspection |
| Why 5 | Not detected |
| Root Cause (Outflow) | Not detected |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Limit switch malfunction happen | D.D. Jopale | 28/04/2024 | 10/04/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No Change, Inspection freq. Double |
| 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) |
Limit switch malfunction while operating 730_Occurance_Before.jpg |
| Occurance (After) |
Limit switch replace by new one 730_Occurance_After.jpg |
| Outflow (Before) |
Parts checked for tapping presence 730_Outflow_Before.jpg |
| Outflow (After) |
Parts checked to ensure complete tapping 730_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All SPM & Tapping Machines |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |