QFR No - 8000873532
Defect Details
| NC No. | 8000873532 |
| NC Date | 06/05/2024 |
| NC Submission Date | |
| Part No. | F2DZ04603B |
| Part Name | FORK BOLT J1A & J1D |
| Supplier Name & Code | 100189-SANGKAJ STEEL PVT LTD. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-THREAD OD U/S, FACE DAMAGE |
1. Problem Description
| Defect Description | THREAD OD U/S |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 2 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualityassurance@sangkaj.com |
| Plant Head/CEO Email ID | steel@sangkaj.com |
| MD Email ID | anirudh.2007@hotmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
500
|
0
|
0
|
350
|
833
|
1683
|
| Check Qty |
500
|
0
|
0
|
350
|
833
|
1683
|
| NG Qty |
2
|
0
|
0
|
1
|
1
|
4
|
| Scrap | 4 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Material at sangkaj Steel End & ETL End Segregated for the above Defect & NG Qty Quantity is Scrapped. |
3. Process Flow
| Process Flow Description |
|---|
| RM Inward-RM Inward Inspection-Traub Blank Cutting-CNC Machining 1st-CNC Machining 2nd-Milling-Deburring-Tapping-Plating -Final Inspection-Dispatch |
4. Process Details
| Process / Operation | CNC Machining 2nd |
| Outsource | Yes |
| Machine / Cell | CNC Machining |
| Machine / Cell No. | 02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Input Material Not OK | Semi-finish Blanks are made from Uniform Diameter Bar, Cut blanks Found OK | O |
| Method | Inadequate inspection method | Only Visual Inspection is done for threading | X |
| Man | Wrong Offset given by operator | defective parts all dimensions found undersize, this happens only due to Wrong Offset | X |
| Tool | Tool Worn out | Insert Worn out doesn`t lead to Dimensions undersize | O |
| Machine | Variation due to Machine | Machine Condition is OK, Not Contributing for Dimension Variation. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Thread Major Dia. Undersize parts found at Customer End |
| Why 2 | During CNC turning, major Diameter became undersize |
| Why 3 | Wrong Offset given by operator |
| Why 4 | Operator was not trained to give offset |
| Why 5 | Training needs to operator not identified and followed. |
| Root Cause (Occurance) | Training needs to operator not identified and followed. |
Root Cause Analysis (Outflow)
| Why 1 | Thread Major Dia. Undersize parts found at Customer End |
| Why 2 | Defective parts didn`t get arrested during Final inspection |
| Why 3 | Only Visual Inspection is done for threading |
| Why 4 | Inadequate inspection method is Followed |
| Why 5 | |
| Root Cause (Outflow) | Inadequate inspection method is Followed |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1.Training given to Operator about giving Offset. 2.Offset Interlocking is done with in 0.1mm. if by mistake operator gives more offset, it will not get executed. | Mr. Santosh Raut | 10/05/2024 | 10/05/2024 | Completed |
| Outflow | Inspection Method Changed, Snap Gauge implemented for 100% Inspection of major Diameter | Mr. Anil Chaudhari | 12/05/2024 | 10/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % Inspection of Major Diameter with Snap gauge of 37.68-37.75mm |
| 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) |
No Offset interlock Provided for the Dimensions, Operator by Mistake can give to much Offset. 785_Occurance_Before.pptx |
| Occurance (After) |
Offset Interlocking is done within 0.1mm, if operator gave offset more than0.1mm, it will not be accepted. 785_Occurance_After.pptx |
| Outflow (Before) |
Only Visual Inspection is done for threading. 785_Outflow_Before.pptx |
| Outflow (After) |
Inspection Method changed, Snap Gauge implemented for Measurement of Major dia. 785_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Fork Bolt AABM |
12. Document Review
| Documents | ControlPlan, WISOP, InspCheckSheet |
| Specify Other Document | None |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | OK |