QFR No - 8000874017
Defect Details
| NC No. | 8000874017 |
| NC Date | 11/05/2024 |
| NC Submission Date | |
| Part No. | F800500507 |
| Part Name | UNDER BRACKET ASSEMBLY |
| Supplier Name & Code | 100061-BAJAJSONS LIMITED |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | THREADING MISSING-M10 THRAED MISS |
1. Problem Description
| Defect Description | M10 Thread Miss in Steering Shaft Bush |
| Detection Stage | Customer End |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | kasingh@bajajsons.com |
| Plant Head/CEO Email ID | crbansal@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 |
440
|
200
|
0
|
0
|
100
|
740
|
| Check Qty |
200
|
0
|
0
|
0
|
100
|
300
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All customer end material 440 pcs. hold for re-inspection & checked 180 pcs. and found all material ok. Warehouse Qty. 200 pcs. will re-check before dispatch to ETL. No material in our End & transit |
3. Process Flow
| Process Flow Description |
|---|
| Press fitting-Mig Welding-Carbon cleaning-Fine boring-Countering at side bore-Slitting-Broaching or deburring-Counter at hole dia 10.5 & 8.8mm-Manual deburring- Phosphating & powder coating-Bore Opening-M6 tapping-M10x1.25 tapping-M6 Tapping-M10x1.25 bush tapping-Parallelism inspection- Die passout-Final inspection-PDI-Packing & dispatch |
4. Process Details
| Process / Operation | Bush Tapping M10x1.25 |
| Outsource | No |
| Machine / Cell | Tapping machine (BDM) |
| Machine / Cell No. | BDM-11 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Machine spindle jam | Machine condition is ok | O |
| Material | Bush Material grade NG | Material is being used as defined grade | O |
| Method | Improper handling NC parts during inspection | During verification found that NC area was defined & followed | O |
| Man | Unskilled manpower | Skilled manpower deployed for tapping & inspection | O |
| Method | Part did not load on fixture for tapping | During verification found that single trolley used at tapping process, chances of part skipped | X |
| Method | PFD not followed during machining process | During verification found that material run as per sequence | O |
| Man | Not Follow up the SOP | During verification found that inspection is being done as per defined SOP | O |
| Method | More then one activities by one checker | During verification & found that more then one activity done during short manpower in Apr,24 | X |
| Tool | Tap wear out | Tool monitoring done as defined | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 5Pcs./Lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Without tapping part reached at next stage |
| Why 2 | Tapping done & without tapping part mix up |
| Why 3 | Mix up due to single trolley used |
| Why 4 | Single trolley used due to less space for input & output trolley at tapping machine |
| Why 5 | Machine lay-out constrain |
| Root Cause (Occurance) | Machine lay-out constrain |
Root Cause Analysis (Outflow)
| Why 1 | Without tapping part skipped from tapping inspection stage of F.I. |
| Why 2 | Checked & without checked parameters part mix-up |
| Why 3 | No marking done after each parameter inspection |
| Why 4 | Marking after inspection was not defined |
| Why 5 | Earlier no such type activities was defined for more then one activities for one checker |
| Root Cause (Outflow) | No marking done after each parameter inspection , resulting without tapping inspection part skipped & reached at customer end |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | OPL made & awareness given to final inspection checker that he will do marking with green paint marker after ensure tapping presence if he will more then one parameters | Mr Irfan | 13/05/2024 | 13/05/2024 | Completed |
| Occurance | Shooter provision to be add at tapping machine for material movement to cover up the space constrain | Mr. Jasbir Singh | 25/05/2024 | 29/05/2024 | Completed |
| Occurance | OJT made & awareness given to all concern for 100% inspection before material move to next stage by machine operator | Mr. Jasbir | 13/05/2024 | 13/05/2024 | Completed |
| Occurance | Poke-yoke provision feasibility to be check after review the sequence change if any | Mr. Harpal Singh | 25/05/2024 | 29/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Green dot marking started after ensure the tapping presence |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 05Pcs/Lot |
10. Evidance of Countermeasure
| Occurance (Before) |
Single trolley is being used for bush tapping process, chances of tapping miss during part taking & loading at trolley from one trolley 801_Occurance_Before.jpg |
| Occurance (After) |
Tray type provision will implemented at tapping machines for material material to next stage, At 1st tapping Input will take from trolley & after that material will move at tray as proposed. Secondly tapping sequence will review again for poke-yoke provision to detect tapping miss issue 801_Occurance_After.jpg |
| Outflow (Before) |
There was no marking after inspection , In this case more then one parameters checked by checker , resulting part move to next stage because no marking was there after inspected parameters 801_Outflow_Before.jpg |
| Outflow (After) |
Green dot marking started after inspection, if single parameter inspection or more then one parameters inspection.(Only one bush hole tapping is checked by checker and other checker checking two tapping left and right side as in bracket. thats why there is no load on bush tapping checker for green marking ) 801_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | K-19,K3,K17AB,K17E ,E101B , U101 & Avenger |
12. Document Review
| Documents | PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | N/A |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | 1. In Occurrence side in Before and After photographs, No change seen. 2. In Occurrence side the Root cause is Machine Layout Constraint, So what Action you have taken for same. 3. In Outflow side the cause seen is that the Final Inspector was overloaded, who is doing multiple activities, earlier multiple activities not carried by one person, then you have added further marking activity, which increase his load also. Then How you assure that only addition of marking will resolve the problem. 4. As this is the Customer complaint for us, But you have shared only Manual controls, Have you initiated any activity for the automated controls for generation and Inspection of these type of Defects. |