QFR No - 8000873537
Defect Details
| NC No. | 8000873537 |
| NC Date | 06/05/2024 |
| NC Submission Date | |
| Part No. | F2DZ15510B |
| Part Name | FORK BOLT -ACJA FF |
| Supplier Name & Code | 100505-A B AUTOCOMPONENTS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-MIX-UP |
1. Problem Description
| Defect Description | Mix-up |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 93 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | headqaabauto@gmail.com |
| Plant Head/CEO Email ID | kamalabautocomponent@gmail.com |
| MD Email ID | abautocomponent@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
500
|
0
|
0
|
300
|
0
|
800
|
| Check Qty |
500
|
0
|
0
|
300
|
0
|
800
|
| NG Qty |
93
|
0
|
0
|
0
|
0
|
93
|
| Scrap | 0 |
| Rework | 93 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Not an regular production, Existing FG verified and segregated. |
3. Process Flow
| Process Flow Description |
|---|
| RM inward-Cutting-Turining-Milling-Final quality-Dispatch |
4. Process Details
| Process / Operation | Turning & Milling |
| Outsource | No |
| Machine / Cell | CNC & VMC |
| Machine / Cell No. | CNC20 & VMC2 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Similar part production | 13510 & 15510 same time FG | O |
| Man | Unaware & not inspected | Similarity in visual, only length got vary. | O |
| Tool | Tool offset error | Diffrent parts | O |
| Machine | Mixup in the work station | Same trays used | O |
| Material | Same Grade material issued | Same material | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 1-100 |
7. Root Cause Analysis (Occurance)
| Why 1 | NOT AS PER SPECIFICATION-MIX-UP |
| Why 2 | Both Regular (F2DZ15510B) & Development part (F2DZ12810B) Anodizing done same location. |
| Why 3 | As per customer demand Anodizing done the regular part as well as development part. |
| Why 4 | For regular parts dispatch as per the schedule, during development stage Only 5 to 10 samples are dispatched, Balance parts are sent it later. |
| Why 5 | As per customer requirement. |
| Root Cause (Occurance) | Parts mix up happened during Anodizing stage. |
Root Cause Analysis (Outflow)
| Why 1 | NOT AS PER SPECIFICATION-MIX-UP |
| Why 2 | Both Regular (F2DZ15510B) & Development parts (F2DZ12810B) are kept at final inspection area. |
| Why 3 | Before dispatching final inspection to be done. |
| Why 4 | As per ISO / IATF standard requirement. |
| Why 5 | To supply the defect free products. |
| Root Cause (Outflow) | Due to lack of knowledge & confusion parts got mixed up. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Plan the diffrent interval for machining. | Planning | 20/05/2024 | 10/05/2024 | Completed |
| Outflow | Plan the dedicated person to pack the FG`s | Quality head | 20/05/2024 | 10/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | If similarity in visual, Before packing verify the diameter and length of the parts. |
| 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) |
Machine Plan similar parts same intervals 789_Occurance_Before.xlsx |
| Occurance (After) |
Machine plan deffrent intervals. 789_Occurance_After.xlsx |
| Outflow (Before) |
Without part Weight . 789_Outflow_Before.xlsx |
| Outflow (After) |
With part weight.CP AND FMEA UPDATED 789_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | N/A |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | N/A |
13. Effectiveness Of Action
| Reviewed Quantity | 70 |
| Reason for submission | Root cause analysis can do better |