QFR No - 8000872766
Defect Details
| NC No. | 8000872766 |
| NC Date | 02/05/2024 |
| NC Submission Date | |
| Part No. | S2KH01502B |
| Part Name | REBOUND SPRING K55G |
| Supplier Name & Code | 100185-HELICAL SPRINGS |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | BEND-SHARP EDGE AND BEND |
1. Problem Description
| Defect Description | Bend and sharp edge |
| Detection Stage | Warranty |
| Problem Severity | Function |
| NG Quantity | 5 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | sego1mwjmrqh0ahtoh5qj3yl.jpg |
Supplier Communication Details
| Quality Head Email ID | Prabhat@helicalsprings.in |
| Plant Head/CEO Email ID | awadhwa@helicalsprings.in |
| MD Email ID | ataneja@helicalsprings.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
0
|
0
|
0
|
1200
|
0
|
1200
|
| Check Qty |
0
|
0
|
0
|
1200
|
0
|
1200
|
| NG Qty |
0
|
0
|
0
|
3
|
0
|
3
|
| Scrap | 3 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| all suspected material hold in Quarantine area for reverification |
3. Process Flow
| Process Flow Description |
|---|
| Rm inspection -coiling - SR - Grinding - Sp- SR2-Scragging - surface treatment - pdi - packing - dispatch |
4. Process Details
| Process / Operation | CNC grinding |
| Outsource | No |
| Machine / Cell | CNC Grinding |
| Machine / Cell No. | N/A |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Chamfer not available in guide plate | chamfer check & found not available | X |
| Machine | Preventive maint not done | machine pm checked & found ok | O |
| Man | Unskilled manpower | skill matrix checked & found | O |
| Tool | Tool worn out | physically tool check & found ok | O |
| Material | Rm not as per grade | Rm checked & found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 nos |
7. Root Cause Analysis (Occurance)
| Why 1 | End coil bend in spring |
| Why 2 | End Coil distorted during Grinding Process |
| Why 3 | End coil stuck with guide plate in grinding process |
| Why 4 | Level difference at junction of guide plate |
| Why 5 | sharp corner observed at the edge of guide plate (entry ) |
| Root Cause (Occurance) | sharp corner observed at the edge of guide plate (entry ) |
Root Cause Analysis (Outflow)
| Why 1 | End Coil bend in spring |
| Why 2 | Minor bend not detected at final stage |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Minor bend not detected at final stage |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Limit sample displayed at WIP Area | Sunil | 30/04/2024 | Completed | |
| Occurance | Training & awareness given to team | sonu upadhyay | 30/04/2024 | Completed | |
| Outflow | 100 % inspection with Combination gauge OD & ID Both implemented in final stage | Sunil | 10/05/2024 | Completed | |
| Occurance | Chamfer provided at sharp corner of guide plate to ensure smooth transition of spring from grinding wheel to guide plate | Arvind | 10/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % inspection with combination gauge |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
10. Evidance of Countermeasure
| Occurance (Before) |
BEFORE - Chamfer not available in guide plate 772_Occurance_Before.xlsx |
| Occurance (After) |
AFTER -Chamfer provided in Guide plate 772_Occurance_After.xlsx |
| Outflow (Before) |
Before - Visual inspection 772_Outflow_Before.xlsx |
| Outflow (After) |
after - Combination pin gauge used for inspection 772_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Model - k55 |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, ProcessFlowChart |
| Specify Other Document | OPL,Training,Gauge |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | End coil bend in rebound spring K55 |