QFR No - 8000873485
Defect Details
| NC No. | 8000873485 |
| NC Date | 06/05/2024 |
| NC Submission Date | |
| Part No. | F2LG03302B |
| Part Name | SEAT PIPE (B104E |
| Supplier Name & Code | 100648-JOTIBA TECHNOLOGIES PVT.LTD. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-GROOVE OD RUNOUT MORE |
1. Problem Description
| Defect Description | GROOVE OD RUNOUT MORE |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 52 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | accjotiba@gmail.com |
| Plant Head/CEO Email ID | sanghavi.rajesh@sanghavigroup.co.in |
| MD Email ID | jotibatech@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
450
|
0
|
0
|
0
|
0
|
450
|
| Check Qty |
450
|
0
|
0
|
0
|
0
|
450
|
| NG Qty |
52
|
0
|
0
|
0
|
0
|
52
|
| Scrap | 52 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Boring set-up approval time inspect thread runout wrt groove diameter, if runout is ok then start boring operation. |
3. Process Flow
| Process Flow Description |
|---|
| 10.Raw material Inspection ,20.Parting Off 30.Chamfer,40.Weighing,50.Draw Forging,60.Hex Forging,70.Rough Grinding,80.Collar Machining,90.Total length facing and Boring,100.Piercing,110.DF Hole chamfering,120. Compression Hole chamfering, 130.ID Reaming,140.Tapping,150.Finish Grinding,160.Final Inspection,170.ID Cleaning,180.Ultrasonic Cleaning,190.Apply antirust oil,200.Packing and Dispatch |
4. Process Details
| Process / Operation | Total length facing and Boring |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | CNC01, CNC02, CNC05 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Job slip in holding split collet due to collet wear out. | Collet condition is found ok. | O |
| Machine | Axial runout of job and spindle body above 0.1 mm. | Found runout within 0.05 mm | O |
| Man | Chuck jaw was break due to minor accident on machine. | Operator not inspect jaw condition | X |
| Method | Thread runout not inspect at boring setup approval time. | Thread runout inspect at tapping operation done. | X |
| Material | Boring time ID runout excess. | Boring ID runout found 0.12 mm. | 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 | Sampling |
7. Root Cause Analysis (Occurance)
| Why 1 | Thread runout wrt groove diameter is more |
| Why 2 | line mark on boring face. |
| Why 3 | insert corner break. |
| Why 4 | boring time job not clamp properly. |
| Why 5 | chuck jaw was break due to minor accident on the machine but this time jaw condition not inspect. |
| Root Cause (Occurance) | Chuck jaw was break that why job not clamp properly and insert corner is break. |
Root Cause Analysis (Outflow)
| Why 1 | Thread runout wrt groove diameter is more. |
| Why 2 | Excess runout piece not detect at final inspection side. |
| Why 3 | due to inspect runout at final inspection sampling basis. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Runout inspection frequency is low at final inspection. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Runout sampling inspection frequency increase at final inspection time. | Gopinath Gore | 17/06/2024 | 17/06/2024 | Completed |
| Occurance | Start inspection at time boring done and also start daily chuck jaw condition. | Gaurav Mhaske | 11/05/2024 | 11/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | start inspection at time of boring setup approval. |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | Sampling. |
10. Evidance of Countermeasure
| Occurance (Before) |
Thread runout wrt groove diameter inspection not done boring setup approval time. 778_Occurance_Before.xlsx |
| Occurance (After) |
Thread runout wrt groove diameter inspection done boring setup approval time and CNC Chuck jaw inspection done. 778_Occurance_After.xlsx |
| Outflow (Before) |
Before Sampling plan inspection frequency. 778_Outflow_Before.xlsx |
| Outflow (After) |
Revise sampling plan frequency change. 778_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | No |
12. Document Review
| Documents | ControlPlan, InspCheckSheet |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | OK |