QFR No - 8000874506
Defect Details
| NC No. | 8000874506 |
| NC Date | 16/05/2024 |
| NC Submission Date | |
| Part No. | 520DZ00212 |
| Part Name | FORK BOLT K60-(DS181012) |
| Supplier Name & Code | 100189-SANGKAJ STEEL PVT LTD. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-DIMN. 7.5 UNDERSIZE - (4.0+0.1) + (3.5 ) |
1. Problem Description
| Defect Description | DIMN. 7.5 UNDERSIZE - (4.0+0.1) + (3.5 ) |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 402 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualityassurance@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 |
1600
|
0
|
0
|
800
|
1000
|
3400
|
| Check Qty |
1600
|
0
|
0
|
800
|
1000
|
3400
|
| NG Qty |
402
|
0
|
0
|
36
|
0
|
438
|
| Scrap | 436 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material at ETL End & at Sangkaj Steel is segregated, Defective Qty is scrapped. |
3. Process Flow
| Process Flow Description |
|---|
| RM Inward-RM Inward inspection-Traub Machining(Semi-finish Blank)-Grinding-Tapping-Thread Rolling-Plating-Final Inspection-Packing & dispatch |
4. Process Details
| Process / Operation | Traub Machining |
| Outsource | Yes |
| Machine / Cell | Traub machine |
| Machine / Cell No. | 04 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Tool Worn Out | Worn Out Tool Doesn`t Cause huge Variation | X |
| Man | New or Unskilled operator | Experienced & Skilled Operator is deputed for production | X |
| Material | Input Material not ok | Part manufactured through Continuous bar Feeding & RM Bar Found OK | X |
| Method | Inadequate Inspection Method | No Checkpoint for the Parameter in the Inprocess & in Final Inspection. | O |
| Machine | Variation due to Machine | Machine Condition found ok | X |
| Tool | Wrong Tool Used | part produced by using another tool used for similar category Parts | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 50:500 |
7. Root Cause Analysis (Occurance)
| Why 1 | 7.50 mm Dimension found undersize |
| Why 2 | Wrong forming Tool used for machining |
| Why 3 | Forming Tools not identified with Part Names. |
| Why 4 | Tool Identification not mentioned in the WI |
| Why 5 | |
| Root Cause (Occurance) | Tool Identification not mentioned in the WI |
Root Cause Analysis (Outflow)
| Why 1 | 7.50 mm Dimension found undersize |
| Why 2 | Defective Parts Skipped from Inspection. |
| Why 3 | During Inspection this parameter is not checked |
| Why 4 | Verification of this parameter not Included in Inspection Checklists. |
| Why 5 | Inspection Checklists are inadequate. |
| Root Cause (Outflow) | Inspection Checklists are Inadequate |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 7.50mm Dimension Verification added in Following Checklists- 1. Supplier In-process Inspection Report, 2.Supplier PDIR Report, 3.Sangkaj Steel`s Inward Inspection Report 4.PDIR | Mr. Anil Chaudhari | 03/06/2024 | 03/06/2024 | Completed |
| Occurance | 1.Forming Tools are identified with Part names. 2.Setting WI Updated, it is mentioned in the WI that Every Tool should have Part Names on them. | Mr. Anil Chaudhari | 03/06/2024 | 03/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Dimension 3.50mm Added In Supplier PDIR, Supplier In-process Inspection Report, Inward Inspection & PDI Report of Sangkaj Steel. Inspection will be Followed on Sampling Basis. |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 50:500 |
10. Evidance of Countermeasure
| Occurance (Before) |
No Identification of Forming Tool with part Names 809_Occurance_Before.pptx |
| Occurance (After) |
Part Names Engraved on the Tool with manual Engraving Machine 809_Occurance_After.pptx |
| Outflow (Before) |
No Checkpoint Available for this Dimension 809_Outflow_Before.pptx |
| Outflow (After) |
Checkpoint added in the PDIR, Hourly inspection and Inward Inspection Report 809_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Fork Bolt JD, 5TSF |
12. Document Review
| Documents | ControlPlan, InspCheckSheet |
| Specify Other Document | PDIR |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | Judgment wrong Occurrence side root cause can do better |