QFR No - 8000872282
Defect Details
| NC No. | 8000872282 |
| NC Date | 24/04/2024 |
| NC Submission Date | |
| Part No. | 550FA19033 |
| Part Name | FORK PIPE M/CED-(HMS-30 & HMP-30) |
| Supplier Name & Code | 101186-SANGKAJ BRIGHT WIRES PRIVATE L |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | THREADING NOT OK-M26 THREAD NO GO QUALITFY |
1. Problem Description
| Defect Description | Fork pipe M26 x 1-6H Thread No Go Qualify and After Assembly Mating Part Open in process due to thread NG. |
| Detection Stage | Inprocess |
| Problem Severity | Safety |
| NG Quantity | 11 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | sx54kcwuj1hqagksy3cngh00.jpg |
Supplier Communication Details
| Quality Head Email ID | shivpal@sangkaj.com |
| Plant Head/CEO Email ID | steel@sangkaj.com |
| MD Email ID | anirudh.2007@hotmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
15500
|
0
|
0
|
4900
|
0
|
20400
|
| Check Qty |
15500
|
0
|
0
|
4900
|
0
|
20400
|
| NG Qty |
11
|
0
|
0
|
2
|
0
|
13
|
| Scrap | 13 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| segregation of all fork pipe line material at customer ETL Halol as well as inhouse |
3. Process Flow
| Process Flow Description |
|---|
| 000.Receipt of Material, 010 inward inspection, 020 CNC Turn1st, 030 CNC Turn-2nd , 040 Drilling, 050 Final Inspection, 060 Anti Rust Oil Application, 070Air Cleaning, 080 Dispatched |
4. Process Details
| Process / Operation | 020 CNC Turn1st |
| Outsource | No |
| Machine / Cell | CNC fork pipe |
| Machine / Cell No. | CNC 02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | WEAR OFFSET LOCK | WEAR OFFSET NOT LOCK IN CNC MACHINE | X |
| Man | NEW OPERATOR | SKILLED OPERATOR | O |
| Material | MATERIAL HARDNESS MORE | MATERIAL HARDNESS OK | O |
| Method | INSERT CHANGE WI | INSERT CHANGE WI NOT AVAILABLE | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5nos/hrs |
7. Root Cause Analysis (Occurance)
| Why 1 | M26X1-6H Threading NO-GO Tight |
| Why 2 | threading minor diameter was at higher side |
| Why 3 | at the time of correction operator taken 0.3mm offset instead of 0.03mm |
| Why 4 | wrong offset given by operator |
| Why 5 | wear offset not lock in CNC machine |
| Root Cause (Occurance) | Wear offset not lock in CNC Machine. |
Root Cause Analysis (Outflow)
| Why 1 | M26X1-6H Threading No-Go Tight |
| Why 2 | Inspection skipped by Operator and line Inspector |
| Why 3 | Inspection Done On Sampling Basis. (5 Nos / Lot) |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspection Done On Sampling Basis. (5 Nos / Lot). |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | At Final Inspection stage we have started the 100% inspection at with the help of thread plug gauge up to till date no any defective part found. We will doining inspectionupto 15.05.2024. Then we will doing inspection as per IS 2500 Standard. | Mr. Amol Rathod | 25/04/2024 | 25/04/2024 | Completed |
| Occurance | wear offset locked by 0.03mm in CNC machine | Mr. Bijay maity | 25/04/2024 | 25/04/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Inspection with the help of thread plug gauge & plug gauge before supply the ETL With identification mark on Ok Part. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | ALL PART |
10. Evidance of Countermeasure
| Occurance (Before) |
Wear offset not lock in CNC machine. 756_Occurance_Before.jpg |
| Occurance (After) |
Wear Offset locked By 0.03mm In CNC Machine. 756_Occurance_After.jfif |
| Outflow (Before) |
Final Inspection Stage Frequency has 5 Nos/Lot 756_Outflow_Before.jpeg |
| Outflow (After) |
At Final Inspection stage we have started the 100% inspection at with the help of thread plug gauge up to till date no any defective part found. We will doing inspection unto 15.05.2024. Then we will doing inspection as per IS 2500 Standard 756_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | FORK PIPE HMS30& HMP30 (550FA19033) |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | 500 part checked not ok part not found |