QFR No - 8000873486
Defect Details
| NC No. | 8000873486 |
| NC Date | 06/05/2024 |
| NC Submission Date | |
| Part No. | F2LG03702B |
| Part Name | SEAT PIPE (K1 UG) |
| Supplier Name & Code | 100648-JOTIBA TECHNOLOGIES PVT.LTD. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-THREADING INCOMPLETE |
1. Problem Description
| Defect Description | THREADING INCOMPLETE |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 1 |
| 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 |
1050
|
0
|
0
|
1200
|
2000
|
4250
|
| Check Qty |
1050
|
0
|
0
|
1200
|
2000
|
4250
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Model wise marking on spacer plate of job stopper. |
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 | 140.Tapping |
| Outsource | No |
| Machine / Cell | Tapping |
| Machine / Cell No. | Tapping 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Tap use excess compare to tap life set that why wear out coating of tap. | Set interlock of machine tap life. | O |
| Tool | No model wise marking on spacer plate. | Not inspect spacer plate size. | O |
| Machine | PM not done on time. | PM done on time. | O |
| Material | Input size of bore diameter undersize. | Input size of bore is found ok. | O |
| Man | Not inspect spacer plate before assembly of stopper. | Operator knows only who to assembly of stopper. | X |
| Method | There is no cross verification of after setup ok or not ok | Operator not know how to check setup ok or Not ok. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | Sampling |
7. Root Cause Analysis (Occurance)
| Why 1 | Half tapping part produce. |
| Why 2 | While set-up changing time wrong width spacer plate use. |
| Why 3 | Operator not check width of spacer plate during set-up time. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | No model wise marking on spacer plate of stopper. |
Root Cause Analysis (Outflow)
| Why 1 | Half tapping part not detect at final inspection. |
| Why 2 | Inspect part at final inspection is visually. |
| Why 3 | Available thread plug gauge for inspection thread but length GO thread gauge is less. |
| Why 4 | No special gauge for inspection half tapping job. |
| Why 5 | |
| Root Cause (Outflow) | No special gauge for inspection of half tapping job. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | After setup change cross check setting is ok or not ok use setting block. | Gopinath Gore | 06/06/2024 | 03/06/2024 | Completed |
| Occurance | Model wise mark on spacer plate. | Gopinath Gore | 08/05/2024 | 08/05/2024 | Completed |
| Outflow | Add special gauge for inspection with 100% identification mark on job. | Gopinath Gore | 11/05/2024 | 11/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection with identification mark on job and add special gauge for inspection of tapping. |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | sampling |
10. Evidance of Countermeasure
| Occurance (Before) |
No identification mark on spacer plate of stopper. 779_Occurance_Before.xlsx |
| Occurance (After) |
Identification mark on spacer plate of stopper. 779_Occurance_After.xlsx |
| Outflow (Before) |
Inspect part as per sampling plan and visually. 779_Outflow_Before.xlsx |
| Outflow (After) |
100% Visually inspection with identification mark and use special gauge for checking. 779_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | Special Gauge |
13. Effectiveness Of Action
| Reviewed Quantity | 150 |
| Reason for submission | Ok |