QFR No - 8000879364
Defect Details
| NC No. | 8000879364 |
| NC Date | 22/06/2024 |
| NC Submission Date | |
| Part No. | 550PC09107 |
| Part Name | UNDER BKT M/C (CT100) |
| Supplier Name & Code | 101222-SANGKAJ ENGINEERING PVT LTD- U |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | THREADING NOT OK-UNDER BKT RUSTY |
1. Problem Description
| Defect Description | UNDER BKT RUSTY |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 40 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | aslam@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 |
598
|
0
|
0
|
600
|
0
|
1198
|
| Check Qty |
598
|
0
|
0
|
600
|
0
|
1198
|
| NG Qty |
40
|
0
|
0
|
12
|
0
|
52
|
| Scrap | 0 |
| Rework | 52 |
| Under Deviation | 0 |
| Containment Action |
|---|
| checked All ETL End and SEPL End stock |
3. Process Flow
| Process Flow Description |
|---|
| forging inward- pre drilling- ruff boring- 5.1 drilling -boss drilling-lug milling- slitting-counter drilling-M6 tapping-M8 tapping-final inspection-dispatch. |
4. Process Details
| Process / Operation | Sliiting |
| Outsource | No |
| Machine / Cell | Ubkt semifinish line |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Anti rust oil application not done | verified anti rust oil application not done properly | X |
| Machine | Coolant concentration not as per Cantrol plan | verified coolant concentration not ok as per cantrol plan | X |
| Method | INSPECTION NOT DONE AS PER SOP | VERIFRIED INSPECTION DONE AS PER SOP | O |
| Material | raw material receipt rusty | verified material receipt ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 nos |
7. Root Cause Analysis (Occurance)
| Why 1 | UNDER BKT RUSTY |
| Why 2 | coolant concentration found at not ok as per cantrol plan |
| Why 3 | operator not top-up cutting oil after water refilling |
| Why 4 | unskilled operator |
| Why 5 | |
| Root Cause (Occurance) | coolant concentration found at not ok as per control plan. |
Root Cause Analysis (Outflow)
| Why 1 | UNDER BKT RUSTY |
| Why 2 | Anti rust oil application not done properly |
| Why 3 | unskilled inspector |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | skipped form inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | training given to all new unskilled inspector for anti rust oil application. | mr.sonawane | 29/06/2024 | 02/07/2024 | Completed |
| Occurance | after top-up water & cutting oil checking started. | mr.dhage | 29/06/2024 | 02/07/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | no change |
| Inspection Method | Other |
| Other Inspection Method | visual inspection. |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 nos |
10. Evidance of Countermeasure
| Occurance (Before) |
coolant concentration not checked after top-up 883_Occurance_Before.jfif |
| Occurance (After) |
coolant concentration checking started after top-up 883_Occurance_After.jfif |
| Outflow (Before) |
anti rust oil application not done properly 883_Outflow_Before.jfif |
| Outflow (After) |
Training given to all inspector for anti rust oil application 883_Outflow_After.jfif |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | N/A |
12. Document Review
| Documents | WISOP |
| Specify Other Document | Work Instruction |
13. Effectiveness Of Action
| Reviewed Quantity | 150 |
| Reason for submission | OK |