QFR No - 8000879355
Defect Details
| NC No. | 8000879355 |
| NC Date | 22/06/2024 |
| NC Submission Date | |
| Part No. | F2DZ04603B |
| Part Name | FORK BOLT J1A & J1D |
| Supplier Name & Code | 100189-SANGKAJ STEEL PVT LTD. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | THREADING NOT OK-M10 THREAD MISSING |
1. Problem Description
| Defect Description | M10 THREAD MISSING |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| 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 |
384
|
0
|
0
|
816
|
0
|
1200
|
| Check Qty |
384
|
0
|
0
|
816
|
0
|
1200
|
| NG Qty |
0
|
0
|
0
|
0
|
0
|
0
|
| Scrap | 0 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation of the Available stock at Customer End done. Rechecking of RF Material Completed. |
3. Process Flow
| Process Flow Description |
|---|
| RM inward - RM Inward Inspection - S/F Blank (Traub Machining) - CNC turning 1st - CNC Turning 2nd - Milling - Tapping- plating-Final Inspection-Packing & Dispatch |
4. Process Details
| Process / Operation | Tapping |
| Outsource | No |
| Machine / Cell | Tapping Cell |
| Machine / Cell No. | 03 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Inadequate Inspection method | Sampling Inspection of M10 Threads is done along with 100% Visual Inspection | X |
| Method | Operation finished & unfinished parts Mix-up | Operator observed keeping both operation done & remained parts on machine | X |
| Tool | Tap Worn Out | Tap Condition Verified, Found Ok | O |
| Material | Input Material Drill ID Oversize | Drill ID found ok, Specified 8.50+0.1, observed 8.58mm | O |
| Machine | Stroke length set less | fixed c-type Stopper has been installed between the two Dodge to Set Tapping length | O |
| Man | Unskilled operator | Skilled Operator Deployed on Machine, Skill Level L2, Verified Skill matrix, Found Ok | 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 | 05 Nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Part Without Threads found at Customer end |
| Why 2 | Without operation part mixed up with finished part on machine |
| Why 3 | Both operation Finished & unfinished parts are kept on Machine. |
| Why 4 | Operator not Followed the Standard Work instruction. |
| Why 5 | |
| Root Cause (Occurance) | Operator not Followed Standard Work Instruction. |
Root Cause Analysis (Outflow)
| Why 1 | Part Without Threads found at Customer end |
| Why 2 | Operation missing part Skipped from Final Inspection |
| Why 3 | Sampling Inspection done for threading with TPG |
| Why 4 | Inadequate sample size during Final inspection |
| Why 5 | |
| Root Cause (Outflow) | Inadequate sample size during Final inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 1. Sample size Increased for Inspection with TPG & 100% Inspection with M10 thread Minor Dia. PPG. Training given to Inspector. Q- Alert Displayed on machine and at Final Inspection. | Mr. Anil Chaudhari | 25/06/2024 | 25/06/2024 | Completed |
| Occurance | 1.Training given to operator about the Proper Working Method. 2.Output bin Kept within reach of operator near machine. | Mr. Santosh Raut | 25/06/2024 | 25/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Inspection of threading Minor Diameter with no-Go PPG along with visual inspection. Without operation parts will get Detected by PPG. |
| 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) |
operator kept both input And output material on Machine 884_Occurance_Before.pptx |
| Occurance (After) |
Training given to operator to Follow the Work Instruction and keep input /output material Separately to avoid the Chances of mixup. 884_Occurance_After.pptx |
| Outflow (Before) |
100% Visual Inspection & Sampling Inspection done with TPG 884_Outflow_Before.pptx |
| Outflow (After) |
100% Inspection with threading minor Diameter PPG to Detect the operation missing part. 884_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Fork Bolt |
12. Document Review
| Documents | ControlPlan, InspCheckSheet |
| Specify Other Document | Inspection Standard |
13. Effectiveness Of Action
| Reviewed Quantity | 250 |
| Reason for submission | OK |