QFR No - 8000873533
Defect Details
| NC No. | 8000873533 |
| NC Date | 06/05/2024 |
| NC Submission Date | |
| Part No. | 550DZ04002 |
| Part Name | FORK BOLT - 5TSF |
| Supplier Name & Code | 100189-SANGKAJ STEEL PVT LTD. |
| 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 | 4 |
| 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 |
0
|
0
|
0
|
700
|
0
|
700
|
| Check Qty |
0
|
0
|
0
|
700
|
0
|
700
|
| NG Qty |
0
|
0
|
0
|
1
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Sangkaj Steel End all FG Material Segregated and no NG Qty found. No material available at customer end. |
3. Process Flow
| Process Flow Description |
|---|
| RM Inward-RM Inspection-Traub Machining-Grinding-Milling-Deburring-Tapping-Rolling-Plating-FInal Inspection-Dispatch |
4. Process Details
| Process / Operation | Thread Rolling |
| Outsource | No |
| Machine / Cell | Thread Rolling Machine |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | New operator | Thread Rolling done by Experienced Operator | O |
| Method | Inadequate Inspection Method | Threads are Checked Visually Only | X |
| Material | Input Material not OK | Input material having Pre-roll Diameter within Specification, | O |
| Tool | Tool Wear out | Thread Rolls life was not Over, Resharpening done Recently | O |
| Method | Setup Part Mix up | operator Setting method observed unsatisfactory, this may have lead to setup piece mix-up | X |
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 | Threading Washout Parts Found at Customer End |
| Why 2 | Threads Not Completely formed during Rolling |
| Why 3 | While Setting Full Pressure not Applied on Parts |
| Why 4 | Setting Parts produced on Low Pressure not kept Separately and got mixed up with OK parts after Setting. |
| Why 5 | |
| Root Cause (Occurance) | Setting Parts Mix-up |
Root Cause Analysis (Outflow)
| Why 1 | Threading Washout Parts Found at Customer End |
| Why 2 | Threads Washout parts skipped from Final Inspection |
| Why 3 | threads are checked Visually only & in visual inspection inspector not able to arrest such parts. |
| Why 4 | Single Inspector Need to check multiple parameters related to aesthetics` along with threading |
| Why 5 | Inspection Method is not proper. |
| Root Cause (Outflow) | Inspection Method is not proper. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | During Visual Inspection, single Inspector checks for all visual Defects Including threading, due to this by mistake defective threading Parts skips to customer End. To avoid this one more Inspector is Deputed for inspection of threading. Along with Visual Inspection 100% major Diameter Inspection with PRG will be done. | MR. Anil Chaudhari | 13/05/2024 | 13/05/2024 | Completed |
| Occurance | On thread Rolling Machine, Closed bins for Rejection & Rework are Provided having One way Entry. Operator will keep the Setup Parts in these bins depending on Inspection Result. As these bins are for one way entry only, reduces the chances Part Mix-up. Also Instructions given to Operator to take part for setting identified with red paint to get it recognized visually if by mistake got mixed up in ok parts. | Mr. Anil Chaudhari | 15/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% threading Major Dia. Inspection with Ring gauge of 25.65mm |
| 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) |
During Setup, Operator Directly mix Setup Pieces in regular ok material. 786_Occurance_Before.pptx |
| Occurance (After) |
Closed Rework & Rejection bins having one way Entry are Provided on Machines. Also part taken for Setup to be identified with Red Paint to make it visually recognizable in OK parts. 786_Occurance_After.pptx |
| Outflow (Before) |
Only Visual Inspection is done for Threading 786_Outflow_Before.pptx |
| Outflow (After) |
Inspection Method is changed, 100% Inspection of major Diameter is Implemented 786_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Fork Bolt having M26X1-6g threading |
12. Document Review
| Documents | ControlPlan, WISOP, InspCheckSheet |
| Specify Other Document | None |
13. Effectiveness Of Action
| Reviewed Quantity | 150 |
| Reason for submission | OK |