QFR No - 8000878738
Defect Details
| NC No. | 8000878738 |
| NC Date | 18/06/2024 |
| NC Submission Date | |
| Part No. | 520HK00102 |
| Part Name | LIP SEAL SUPPORT |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | DIAMETER OVER SIZE-OD OVERSIZE |
1. Problem Description
| Defect Description | OD observation 51.596 mm (OD Oversize) against specification 51.556~51.575 mm. |
| Detection Stage | Customer End |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@sharp-engineers.com |
| Plant Head/CEO Email ID | kurund.ma@sharp-engineers.com |
| MD Email ID | urkhandelwal@sharp-engineers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
0
|
0
|
112
|
0
|
2112
|
| Check Qty |
2000
|
0
|
0
|
112
|
0
|
2112
|
| NG Qty |
1
|
0
|
0
|
112
|
0
|
113
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All pipeline material checked for OD with Identification Tag |
3. Process Flow
| Process Flow Description |
|---|
| Rm inward-Parting-Normalizing-CNC 1st-CNC2nd-CNC3rd-Final Inspection-PDI-Packing and Forwarding |
4. Process Details
| Process / Operation | CNC |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | CNC |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled Operator | Skilled manpower deployed | O |
| Material | Incorrect RM Grade | Material found ok as per TC | O |
| Method | Insert Not Change at defined frequency | Insert change at defined frequency but Part not validated by operated | X |
| Method | Part not validated after replacement of insert | affect | X |
| Material | Hardness Variation in RM | Hardness found ok as per specification | O |
| Method | Part not clamp properly | Clamping pressure found ok as per process parameter | O |
| Machine | Power cut | No effect as we are Rejecting all power cut parts | O |
| Machine | Insert Broken | Operator Doing inspection with APG for ID and visual 100%. | O |
| Machine | Insert Wearout | No effect | O |
| Tool | Insert Change | Variation in dimensions | X |
| Method | Fixture Not clean Properly | Fixture cleaning done as per SOP | O |
| Man | Wrong setting done by operator | Setting done ok also setup approval report evident | O |
| Material | Variation in RM OD | No effect | O |
| Man | New manpower | Regular manpower deployed | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 0 |
7. Root Cause Analysis (Occurance)
| Why 1 | OD oversized |
| Why 2 | Observed 51.596mm against 51.556~51.575mm |
| Why 3 | Insert changed and part not verify by operator and supervisor. |
| Why 4 | No Pokayoke for insert life monitoring |
| Why 5 | |
| Root Cause (Occurance) | No Pokayoke for insert life monitoring |
Root Cause Analysis (Outflow)
| Why 1 | OD oversized |
| Why 2 | Skip from inspection |
| Why 3 | Part not validated by operator or supervisor. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Part not validated by operator or supervisor. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Combining all CNC operation 40,50&60 in One Setup to avoid defect also New machine having pokayoke for insert change. | Manoj Kadam | 26/06/2024 | 26/06/2024 | Completed |
| Outflow | Only Supervisor can Clear insert change alarm after verification of part becouse tool life programing is protected with key. | Pankaj Khadse | 26/06/2024 | 26/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NA |
| 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) |
No Pokayoke for insert life monitoring, 875_Occurance_Before.pdf |
| Occurance (After) |
Combining all CNC operation 40,50&60 in One Setup to avoid defect also New machine having pokayoke for insert change. 875_Occurance_After.pdf |
| Outflow (Before) |
Part not validated by operator or supervisor. 875_Outflow_Before.jpeg |
| Outflow (After) |
Only Supervisor can Clear insert change alarm after verification of part because tool life programing is protected with key. 875_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, ProcessFlowChart |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | OD observation 51.596 mm (OD Oversize) against specification 51.556~51.575 mm |