QFR No - 8000873540
Defect Details
| NC No. | 8000873540 |
| NC Date | 06/05/2024 |
| NC Submission Date | |
| Part No. | 550PC09107 |
| Part Name | UNDER BKT M/C (CT100) |
| Supplier Name & Code | 101222-SANGKAJ ENGINEERING PVT LTD- U |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-ID UNDERSIZE |
1. Problem Description
| Defect Description | ID UNDERSIZE |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 6 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | irfan@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 |
320
|
0
|
0
|
0
|
0
|
320
|
| Check Qty |
320
|
0
|
0
|
0
|
0
|
320
|
| NG Qty |
6
|
0
|
0
|
0
|
0
|
6
|
| Scrap | 6 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| checked all ETL end and pipe line material |
3. Process Flow
| Process Flow Description |
|---|
| forging inward-pre drilling- ruff boring-5.1 drill-boss drilling lug milling- slitting-counter drilling-M6 tapping- M8 tapping- final inspection. |
4. Process Details
| Process / Operation | ruff boring |
| Outsource | No |
| Machine / Cell | under bracket semi finish line |
| Machine / Cell No. | ruff boring |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Inspector did not follow the SOP for inspection | Final inspection report is evident | O |
| Material | Burr generated at rough boring stage | Verified burr not found | O |
| Method | master setting ring not ok | verified master setting ring having ovality and tapper | X |
| Tool | Tool life monitoring not effective | Tool life monitoring found not as per plan | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | 28 mm Center bore ID undersize produced |
| Why 2 | due to tool wear tool size gets undersize |
| Why 3 | tool not changed at defined life |
| Why 4 | No any alarm/information to operator after life over |
| Why 5 | |
| Root Cause (Occurance) | No any alarm/information to operator after life over |
Root Cause Analysis (Outflow)
| Why 1 | 28 mm Center bore ID undersize found at customer end. |
| Why 2 | 28 mm Center bore ID undersize not detected at final inspection. |
| Why 3 | Air gauge master ring found ovality and tapper before calibration due date. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Air gauge master ring found ovality and tapper before calibration due date. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Interlock mechanism for tool life on boring SPM. | Mr.Sayyed | 10/06/2024 | 11/06/2024 | Completed |
| Outflow | Revise calibration frequency from 1 year to 6 Month | Mr.Sayyed | 16/05/2024 | 15/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | Revise calibration frequency from 1 year to 6 Month |
| 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) |
air gauge master setting ring found ovality and tapper 791_Occurance_Before.jpg |
| Occurance (After) |
ok master setting ring provided 791_Occurance_After.jpg |
| Outflow (Before) |
Manual tool life monitoring 791_Outflow_Before.jpg |
| Outflow (After) |
Part counter with buzzer alarm implemented 791_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | SPM ruff boring Machine |
12. Document Review
| Documents | WISOP |
| Specify Other Document | work instruction |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |