QFR No - 8000873489
Defect Details
| NC No. | 8000873489 |
| NC Date | 06/05/2024 |
| NC Submission Date | |
| Part No. | F2LG05302B |
| Part Name | SEAT PIPE - ABWB ENDURO |
| Supplier Name & Code | 100929-HARSHAD ENGINEERING COMPANY |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-THREAD MISSING |
1. Problem Description
| Defect Description | THREAD MISSING |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qaharshad@miteshauto.com |
| Plant Head/CEO Email ID | sjkadam@miteshauto.com |
| MD Email ID | auto.mitesh@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
500
|
200
|
0
|
0
|
0
|
700
|
| Check Qty |
500
|
200
|
0
|
0
|
0
|
700
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % sorting done for ETL End, HEC WIP & FG material |
3. Process Flow
| Process Flow Description |
|---|
| Cutting-Draw-Forging(Head Formation)-Rough Grinding-CNC (Head, Boring & Tapping)-Punching-Finish Grinding-Final Inspection-Packing-Dispatch |
4. Process Details
| Process / Operation | Tapping |
| Outsource | No |
| Machine / Cell | Tapping |
| Machine / Cell No. | 164 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Skip While Visual Inspection | Skip While Inspection | X |
| Machine | Limit Switch setting not ok or Malfunction while working | Limit switch malfunction while working | X |
| Tool | Tap Worn out or damage | Tap found in OK Condition | O |
| Man | Inspection or Checking Skipped | As per Sampling plan parts checked by Inspectors | O |
| Material | Wrong grade material Used | Material grade is ok As per Drawing | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Threading missing |
| Why 2 | During tapping operation tap not performed threading |
| Why 3 | Threading spindle limit switch not working properly |
| Why 4 | Threading limit switch mal-function |
| Why 5 | |
| Root Cause (Occurance) | Threading limit switch mal-function |
Root Cause Analysis (Outflow)
| Why 1 | Threading missing |
| Why 2 | 100% parts not checked at final inspection stage |
| Why 3 | Parts checked on sampling basis |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Parts checked on sampling basis |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | In PM check sheet point added for Limit switch checking | MMS | 15/05/2024 | 17/05/2024 | Completed |
| Occurance | Limit switch changed with new one | Production team | 10/05/2024 | 12/05/2024 | Completed |
| Outflow | 100% parts visually checked at final inspection | QA Team | 03/05/2024 | 08/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% parts checked at final inspection stage with identification |
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Limit switch mal function 782_Occurance_Before.pdf |
| Occurance (After) |
Limit switch changed and in PM check sheet point added 782_Occurance_After.pdf |
| Outflow (Before) |
Parts Checked on sampling basis 782_Outflow_Before.jpg |
| Outflow (After) |
100% Parts Checked for threading presence 782_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | For all model of seat pipe |
12. Document Review
| Documents | ControlPlan, WISOP |
| Specify Other Document | CP, PM checksheet |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | ok |