QFR No - 8000874016
Defect Details
| NC No. | 8000874016 |
| NC Date | 11/05/2024 |
| NC Submission Date | |
| Part No. | F20510907B |
| Part Name | UNDER BRACKET ASSEMBLY K19 DRUM FF |
| Supplier Name & Code | 100297-BAJAJSONS LTD |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | THREADING NOT OK-THREAD LENGTH UNDERSIZE |
1. Problem Description
| Defect Description | Thread Length Undersize observed 10.50 to 11.20 against the specs. 12+1.0 |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 4 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | anuj.saxena@bajajsons.com |
| Plant Head/CEO Email ID | sahadev.singh@bajajsons.com |
| MD Email ID | sanjay.bajaj@bajajsons.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1500
|
0
|
0
|
400
|
2250
|
4150
|
| Check Qty |
1500
|
0
|
0
|
400
|
2250
|
4150
|
| NG Qty |
4
|
0
|
0
|
0
|
0
|
4
|
| Scrap | 4 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material has been segregated at ETL end as well as Bajajsons Roorkee end. |
3. Process Flow
| Process Flow Description |
|---|
| 1-Parting 2-Flaring & Reducing 3-Bush Fitting 4-Bush welding 5-CNC turning 6-Grinding 7-Threading 8-To Assembly |
4. Process Details
| Process / Operation | Threading |
| Outsource | No |
| Machine / Cell | TDR-11/Shaft Line |
| Machine / Cell No. | TDR-11 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled operator. | Unskilled operator | X |
| Machine | Part not proper butting with stopper. | Dust particles stick to stopper face at TDR | 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 | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Threading process was NG |
| Why 2 | Proper part feeding was not ok |
| Why 3 | Part does not rest at stopper face |
| Why 4 | Dust particles stick to stopper face at TDR |
| Why 5 | |
| Root Cause (Occurance) | Dust particles stick to stopper face at TDR |
Root Cause Analysis (Outflow)
| Why 1 | Thread length u/s |
| Why 2 | Only sampling inspection being done at final inspection for thread length checking inspection. |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | 100% Inspection not done at final inspection. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | OPL has been displayed at final inspection. 100% inspection started at FI to check thread length by visually. | Mr. Vikash | 23/05/2024 | 22/05/2024 | Completed |
| Occurance | Training has been given to operator that feeding the part after remove the dust particles at stopper | Mr. Mukesh chauchan | 25/05/2024 | 22/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Visually inspection started |
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Stopper Pic & On Job Training 797_Occurance_Before.jpg |
| Occurance (After) |
Stopper Pic & On job Training 797_Occurance_After.jpg |
| Outflow (Before) |
No OPL displayed 797_Outflow_Before.pdf |
| Outflow (After) |
OPL 797_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | B104D/B105L |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | OK |