QFR No - 8000879354
Defect Details
| NC No. | 8000879354 |
| NC Date | 22/06/2024 |
| NC Submission Date | |
| Part No. | F2LG05402B |
| Part Name | SEAT PIPE - J1A & J1D |
| Supplier Name & Code | 101222-SANGKAJ ENGINEERING PVT LTD- U |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-MIX-UP |
1. Problem Description
| Defect Description | Mix-up |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 5 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | aslam@sangkaj.com |
| Plant Head/CEO Email ID | pardeshinr@snagkaj.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 |
1000
|
0
|
0
|
1000
|
0
|
2000
|
| Check Qty |
1000
|
0
|
0
|
1000
|
0
|
2000
|
| NG Qty |
5
|
0
|
0
|
0
|
0
|
5
|
| Scrap | 5 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation of Pipeline material, Customer end, WIP, Supplier end. |
3. Process Flow
| Process Flow Description |
|---|
| 10.RM Inspection; 20.Parting off and chamfering; 30.Weighing and moly powder application; 40.Draw forging; 50.Head Forging; 60.Rough Grinding; 70A. Collar Machining; 70B. Total length facing, Drilling & Tapping; 80.Hole piercing; 90 DF and Compression hole chamfering; 100.ID Cleaning & Deburring; 110.Finish Grinding; 120.Ultrasonic Cleaning; 130. Final Inspection; 140.Oiling; 150.Packing and storage. |
4. Process Details
| Process / Operation | 140.Final Inspection |
| Outsource | No |
| Machine / Cell | Final Inspection table |
| Machine / Cell No. | FID-SP-01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled operator/Inspector | Found skilled operator | O |
| Tool | Wrong tool used | OK tool used | O |
| Method | Method of handling of rework and rejection Not ok | Rework method not described properly | X |
| Material | Wrong Input material | Material found OK | O |
| Machine | NO input and output stage defined at Machine stage | Input and Output found | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Seat pipe model mix up. |
| Why 2 | Rework of J1A and J1D at FID kept in same bin. |
| Why 3 | Parameters are same in J1A and J1D of rework |
| Why 4 | In rework handling procedure modelwise seperate rework not defined. |
| Why 5 | |
| Root Cause (Occurance) | In rework handling procedure modelwise seperate rework not defined. |
Root Cause Analysis (Outflow)
| Why 1 | Model mix up of seat pipe J1A and J1D found at customer end. |
| Why 2 | Mix up of J1A and J1D seat pipe not detected at FID. |
| Why 3 | After rework of material only rework parameter verified |
| Why 4 | After rework mix up parameter not verified. |
| Why 5 | |
| Root Cause (Outflow) | After rework mix up parameter not verified. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Changes in rework handling procedure for repeat Final inspection for all parameters after rework done. | Mr.Irfan | 01/07/2024 | 01/07/2024 | Completed |
| Occurance | Changes in rework handling procedure for keeping material modelwise and rework parameter wise seperate. | Mr.Irfan | 01/07/2024 | 01/07/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection from initial stage after rework of parts. |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
10. Evidance of Countermeasure
| Occurance (Before) |
No instructions on Modelwise seperate before rework in SOP. 882_Occurance_Before.jpg |
| Occurance (After) |
Seperate material before rework modelwise Instruction added in SOP. 882_Occurance_After.jpg |
| Outflow (Before) |
NO reverification from initial stage of rework material on final inspection. 882_Outflow_Before.jpg |
| Outflow (After) |
Instruction added in rework SOP for reinspection of all material from initial stage on Final inspection. 882_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Not applicable |
12. Document Review
| Documents | WISOP |
| Specify Other Document | NO other document |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | OK |