QFR No - 8000876969
Defect Details
| NC No. | 8000876969 |
| NC Date | 05/06/2024 |
| NC Submission Date | |
| Part No. | F2FA11933B |
| Part Name | FORK PIPE MACHINED - J1D |
| Supplier Name & Code | 101030-TUBE INVESTMENTS OF INDIA LTD |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-SHORT LENGTH |
1. Problem Description
| Defect Description | SHORT LENGTH |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 7 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | AmitVD@tii.murugappa.com |
| Plant Head/CEO Email ID | guptaajay@tii.murugappa.com |
| MD Email ID | mukeshahuja@tii.murugappa.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
500
|
0
|
0
|
1000
|
0
|
1500
|
| Check Qty |
500
|
0
|
0
|
1000
|
0
|
1500
|
| NG Qty |
7
|
0
|
0
|
4
|
0
|
11
|
| Scrap | 11 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Stock available at ETL end & Inhouse checked for the Threading Parameter |
3. Process Flow
| Process Flow Description |
|---|
| Raw Material Inspection- Machining (Cualking & Threading)-Drilling-Oiling-Final Inspection-Dispatch |
4. Process Details
| Process / Operation | Machining |
| Outsource | No |
| Machine / Cell | CNC Machine Cell |
| Machine / Cell No. | M/c No. 22 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 20 nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Total Length Observed Undersize |
| Why 2 | Tube end face not resting properly on Stopper Surface |
| Why 3 | The uneven resting surface of the stopper |
| Why 4 | During Mass production resting surface of the stopper wears out |
| Why 5 | The current Stopper, material used was MS & Not enough which caused the stopper wear out |
| Root Cause (Occurance) | The current Stopper, material used was MS & Not enough which caused the stopper wear out |
Root Cause Analysis (Outflow)
| Why 1 | Not Detected during the Final Inspection & PDIR |
| Why 2 | Inspection on the Sampling Basis |
| Why 3 | No Length Inspection gauge is available for the 100 % Inspection |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No Length Inspection gauge is available for the 100 % Inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | add new height checking gauge | dethe s s | 15/06/2024 | 08/06/2024 | Completed |
| Occurance | Monitoring Started for the Stopper condition Verification during the JH Maintenance which not in practice Erlier | Mr. Dethe SS | 14/06/2024 | 08/06/2024 | Completed |
| Occurance | The Carbide material was used for the new stopper & made Properly hard (50 to 65 HB ) & to prevent loose burr from sticking to the stopper, Also Provision was made for the coolant to come out from the stopper. | Mr. Rathod KS | 03/07/2024 | 03/07/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Length Inspection Gauge Added for the 100 % Inspection |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
10. Evidance of Countermeasure
| Occurance (Before) |
The current Stopper, material used was MS & Not enough which caused the stopper to wear out 836_Occurance_Before.pdf |
| Occurance (After) |
The Carbide material was used for the new stopper & made Properly hard (50 to 65 HB ) & to prevent loose burr from sticking to the stopper, Also Provision was made for the coolant to come out from the stopper. 836_Occurance_After.pdf |
| Outflow (Before) |
Before: No 100 % Inspection on Length Gauge 836_Outflow_Before.pdf |
| Outflow (After) |
After: 100 % Inspection Started by Using Length Inspection Gauge 836_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Model |
12. Document Review
| Documents | WISOP, JHCheckSheet |
| Specify Other Document | WI |
13. Effectiveness Of Action
| Reviewed Quantity | 150 |
| Reason for submission | 1. How much stopper life earlier & now 2. WI for what purpose revised (WI not attached) |