QFR No - 8000873531
Defect Details
| NC No. | 8000873531 |
| NC Date | 06/05/2024 |
| NC Submission Date | |
| Part No. | F2LG07102B |
| Part Name | SEAT PIPE - J1D |
| Supplier Name & Code | 101263-SINGLA PRECISION SCREWS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-TOTAL LENGTH UNDERSIZE |
1. Problem Description
| Defect Description | TOTAL LENGTH UNDERSIZE |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@singlaprecision.com |
| Plant Head/CEO Email ID | quality@singlaprecision.com |
| MD Email ID | aditya@singlaprecision.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
600
|
0
|
0
|
0
|
0
|
600
|
| Check Qty |
600
|
0
|
0
|
0
|
0
|
600
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| STOCK CHECK 100% AT OUR END |
3. Process Flow
| Process Flow Description |
|---|
| 1-RM 2- FORGING 3-PUNCHING -IST 4-ROUGH CLG 5-CNC-IST 6-CNC-II 7-PUNCHING -II 8-I.D CHIP REMOVE 9-REAMING IST 10-REAMING-IIND 11-TAPPING 12-FINAL GRINDING 13-ALKLINE WASHING 14- FINAL INSPECTION 15 - PACKING |
4. Process Details
| Process / Operation | CNC -2ND OPERATION |
| Outsource | No |
| Machine / Cell | CNC-MACHINE |
| Machine / Cell No. | CNC -5 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | RM GRADE AND SIZE NOT OK | VALIDATED AND FOUND OK | O |
| Man | UNAWARENESS OF OPERATOR | VALIDATION AND FOUND MACHINE OPERATOR ABOUT TOOL LIFE FRQ NOT AWARENESS | X |
| Tool | TOOL MAY BE WEAR | VALIDATE AND FOUND WEAROUT | X |
| Method | INSPECTION METHOD NOT EFFECTIVE | VALIDATION AND FOUND TOTAL LENTH CHECKING INSTRUMENT NOT FOUND IN MACHINE | X |
| Machine | MACHINE PM NOT EFFECTIVE | MACHINE AIR GUN NOT WORKING CHIPS NOT CLEAN ON COLLECT | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | NO |
7. Root Cause Analysis (Occurance)
| Why 1 | TOTAL LENGTH UNDERSIZE |
| Why 2 | Due to the presence of a chip in the collect chips the part was not properly set on place |
| Why 3 | Operator Air gun not use |
| Why 4 | OPERATOR WI NOT ADD PART PER CYCLE AIR GUN USE IN COLLET |
| Why 5 | OPERATOR NOT AWRE THIS TYPE OF PROBLEM |
| Root Cause (Occurance) | OPERATOR WI NOT ADD PART PER CYCLE AIR GUN USE IN COLLET |
Root Cause Analysis (Outflow)
| Why 1 | TOTAL LENGTH UNDERSIZE |
| Why 2 | INSPECTION PLAN WAS NOT EFFECTIVE |
| Why 3 | AS PER SAMPLING PLAN PART CHECKING IN FINAL INSPECTION |
| Why 4 | LENGTH DIAL GAUGE NOT AVAILABLE IN MACHINE AND FINAL INSPECTION |
| Why 5 | NG PART SKIPPED FROM INSPECTION AND MACHINE |
| Root Cause (Outflow) | LENGTH DIAL GAUGE NOT AVAILABLE IN MACHINE AND FINAL INSPECTION |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | DIAL LENGTH GAUGE PROVIDE TO MACHINE AND FINAL INSPECTION | MR GANESH MAURYA | 09/05/2024 | 09/05/2024 | Completed |
| Occurance | OPERATOR WI NOT ADD PART PER CYCLE AIR GUN USE IN COLLET | ASHISH SINGH | 09/05/2024 | 09/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | DIAL LENGTH GAUGE PROVIDE TO MACHINE AND FINAL INSPECTION |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 50/1200 |
10. Evidance of Countermeasure
| Occurance (Before) |
OPERATOR WI NOT ADD PART PER CYCLE AIR GUN USE IN COLLET 784_Occurance_Before.xlsx |
| Occurance (After) |
OPERATOR WI ADD PART PER CYCLE AIR GUN USE IN COLLET 784_Occurance_After.xlsx |
| Outflow (Before) |
Gauge not implements 784_Outflow_Before.xlsx |
| Outflow (After) |
100% gauge implements 784_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | CNC -05 PLANT NO -177 |
12. Document Review
| Documents | PokayokeCheckSheet, PFMEA |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | Due to the presence of a chip in the collect chips the part was not properly set on place - Use pokayoke or interlocking like- 1. Seat check pokayoke required to ensure perfect seating/ resting of part 2. Provision of coolant flow with 5 bar pressure interlock with machine cycle. 3. Share pokayoke details |