QFR No - 8000874661
Defect Details
| NC No. | 8000874661 |
| NC Date | 16/05/2024 |
| NC Submission Date | |
| Part No. | F2DZ10910B |
| Part Name | FORK BOLT Ø33 SPD |
| Supplier Name & Code | 100002-CAST AND ALLOYS |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | THREADING NOT OK-THREADE M12X16H UNDER SIZE |
1. Problem Description
| Defect Description | M12 Threading under size |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 115 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | niyati@cast-alloys.com |
| Plant Head/CEO Email ID | shiv.k@cast-alloys.com |
| MD Email ID | dipen@cast-alloys.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1680
|
0
|
0
|
0
|
0
|
1680
|
| Check Qty |
1564
|
0
|
0
|
0
|
0
|
1564
|
| NG Qty |
116
|
0
|
0
|
0
|
0
|
116
|
| Scrap | 116 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % Checked 3 Lots after Complaint |
3. Process Flow
| Process Flow Description |
|---|
| At Machining Stage |
4. Process Details
| Process / Operation | Machining |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | CNC |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Untrained Operator | Skilled Manpower Available | X |
| Man | SOP not Followed | Part Made as per SOP | X |
| Machine | Inadequate Machine Parameters | Machining Parameters are Verified and Found as per Control Plan | X |
| Tool | Tool Wear Out | Tool Condition Found Satisfactory | X |
| Tool | Wrong Tool Selection | Tooling Used as per Process Parameter Checksheet | X |
| Man | Incorrect Tool Offseting | Operator Mistake in Providing Offset for Tool | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 / Batch |
7. Root Cause Analysis (Occurance)
| Why 1 | M12X1 6 H Gauge Under Size |
| Why 2 | During Machining . |
| Why 3 | Incorrect Tool Offset . |
| Why 4 | Operator Error Mistake During Offset Setting . |
| Why 5 | |
| Root Cause (Occurance) | Operator Error Mistake During Offset Setting . |
Root Cause Analysis (Outflow)
| Why 1 | M12X1 6 H Gauge Under Size |
| Why 2 | Missed at Final Inspection stage` |
| Why 3 | Sampling Base Inspection at FI Stage |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Sampling Base Inspection at FI Stage |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1. Retraining Provided to Machining Operator. 2. Supervisor to verify the part after providing any offset . | Naitik Vachani | 19/05/2024 | 19/05/2024 | Completed |
| Outflow | 100 % Inspection Started at Machining Stage & At Final Inspection Stage Three Lots to be 100% Verified | Nitin Chaudhari | 19/05/2024 | 19/05/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Inspection Started at Machining Stage |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 / Batch |
10. Evidance of Countermeasure
| Occurance (Before) |
|
| Occurance (After) |
|
| Outflow (Before) |
|
| Outflow (After) |
|
11. Horizontal Deployment
| Horizontal Deployment Required | |
| Applicable Machine / Model / Plant |
12. Document Review
| Documents | |
| Specify Other Document |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |