QFR No - 8000871813
Defect Details
| NC No. | 8000871813 |
| NC Date | 19/04/2024 |
| NC Submission Date | |
| Part No. | F1GN01102B |
| Part Name | MAIN SPRING K86A |
| Supplier Name & Code | 101236-SUMA SPRINGS PRIVATE LIMITED |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | DIAMETER OVER SIZE-OD MORE ISSUE |
1. Problem Description
| Defect Description | K86 MAIN SPRING OD MORE ISSUE |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 6 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qc@sumasprings.com |
| Plant Head/CEO Email ID | vp@sumasprings.com |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
0
|
0
|
7200
|
0
|
9200
|
| Check Qty |
2000
|
0
|
0
|
7200
|
0
|
9200
|
| NG Qty |
6
|
0
|
0
|
0
|
0
|
6
|
| Scrap | 6 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| .Quality Alert prepared and awareness created among Internal CFT team (Production, QC/QA,Stores,Despatch,QC Inspectors) Segregation Process initiated at entire Pipeline to identify the NG part and to prevent the NG part to reach to customer |
3. Process Flow
| Process Flow Description |
|---|
| COIL+TEM+GRIN+SHOT+SCR+TEM+OILING +PACK+DESPATCH |
4. Process Details
| Process / Operation | COILING |
| Outsource | No |
| Machine / Cell | COILING MACHINE |
| Machine / Cell No. | COILING M/C |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Coiling | Set Setup part mix up during process | O |
| Method | Random sampling method | verified and found Sampling ineffective | 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 | 10% |
7. Root Cause Analysis (Occurance)
| Why 1 | OD more |
| Why 2 | Set up part kept in the regular bin |
| Why 3 | previous shift rejections not cleared |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | previous shift rejections not cleared |
Root Cause Analysis (Outflow)
| Why 1 | NG Parts Not found during PDI |
| Why 2 | PDI done as per AOI |
| Why 3 | PDI inspection not effective |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | PDI inspection not effective |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Instruction provided that Daily 4.30 Pm all rejections to be monitored and moved to scrap yard & Set up rejections only kept in the red bin | Vinay | 11/04/2024 | Completed | |
| Outflow | Sampling quantity % will be increase by 50% more than the existing lot qty at PDI | Moulidharan | 10/04/2024 | 10/04/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Sampling quantity % will be increase by 50% more than the existing lot qty at PDI |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 50% |
10. Evidance of Countermeasure
| Occurance (Before) |
previous shift rejections not cleared 751_Occurance_Before.pdf |
| Occurance (After) |
Instruction provided that Daily 4.30 Pm all rejections to be monitored and moved to scrap yard & Set up rejections only kept in the red bin 751_Occurance_After.pdf |
| Outflow (Before) |
PDI inspection not effective 751_Outflow_Before.pdf |
| Outflow (After) |
Sampling quantity % will be increase by 50% more than the existing lot qty at PDI 751_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | F1GN011020 |
12. Document Review
| Documents | |
| Specify Other Document | Q_ alert - Scrap reg |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |