QFR No - 8000874414
Defect Details
| NC No. | 8000874414 |
| NC Date | 15/05/2024 |
| NC Submission Date | |
| Part No. | 080FA04033 |
| Part Name | FORK PIPE MACHINED |
| Supplier Name & Code | 101222-SANGKAJ ENGINEERING PVT LTD- U |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-THREADING NG |
1. Problem Description
| Defect Description | THREADING NG |
| Detection Stage | Inprocess |
| Problem Severity | Safety |
| NG Quantity | 14 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | aslam@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 |
800
|
0
|
0
|
0
|
0
|
800
|
| Check Qty |
800
|
0
|
0
|
0
|
0
|
800
|
| NG Qty |
14
|
0
|
0
|
0
|
0
|
14
|
| Scrap | 14 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done at ETL end. |
3. Process Flow
| Process Flow Description |
|---|
| Tube RM inward - Induction hardening - CNC 1st - CNC 2nd - Drilling - Visual inspection - Bundling - Dispatch |
4. Process Details
| Process / Operation | CNC-1st |
| Outsource | No |
| Machine / Cell | CNC-05 |
| Machine / Cell No. | CNC-05 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | ID of tube is more than TRD ID | Inward inspection done | X |
| Method | Tool position disturbed | Every thing is controlled by program | X |
| Man | operator did not follow the measuring procedure | Hourly inspection report is updated | X |
| Tool | insert worn-out. | Micro program is available. | O |
| Machine | Turret bearing worn out | PM done on time | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10:500 |
7. Root Cause Analysis (Occurance)
| Why 1 | Fork pipe machined -THREADING NG (Go gauge not qualifying) |
| Why 2 | Insert worn out. |
| Why 3 | insert worn out before defined life in micro program |
| Why 4 | Tool life defined is not ok. |
| Why 5 | Validation for tool life is in adequate. |
| Root Cause (Occurance) | Validation for tool life is in adequate. |
Root Cause Analysis (Outflow)
| Why 1 | Fork pipe machined -THREADING NG (Go gauge not qualifying) |
| Why 2 | Inspection done as per defined frequency ,i.e 10:500. |
| Why 3 | Frequency for inspection is less in CP. |
| Why 4 | CP for final inspection is inadequate. |
| Why 5 | |
| Root Cause (Outflow) | CP for final inspection is inadequate. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Re-validation to be done for tool life. | Mr. Krushna Phuke | 30/05/2024 | 31/05/2024 | Completed |
| Outflow | CP to be updated for inspection frequency. | Mr. Aslam Shaikh | 30/05/2024 | 31/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Frequency of inspection changed from 10:500 to 50:500. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 50:500 |
10. Evidance of Countermeasure
| Occurance (Before) |
CNC program before - tool life defined as per previous experience only 813_Occurance_Before.pdf |
| Occurance (After) |
CNC program after- Tool life defined as per validation report. 813_Occurance_After.pdf |
| Outflow (Before) |
CP - Before ( inspection frequency 10:500 ) 813_Outflow_Before.pdf |
| Outflow (After) |
CP - After ( inspection frequency increased 10:500 to 50:500 813_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All similar models. |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | Accepted |