QFR No - 8000879788
Defect Details
| NC No. | 8000879788 |
| NC Date | 25/06/2024 |
| NC Submission Date | |
| Part No. | 550KH03002 |
| Part Name | REBOUND SPRING-PRFH-006 |
| Supplier Name & Code | 101245-SAGAR SPRINGS PVT LTD |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | MIX UP OTHER MODEL-NOT USING KONF MIXUP AT SAGAR END |
1. Problem Description
| Defect Description | Rebound spring length less and more issue ,mix up at Sagar Supplier end . not using in KONF front fork . |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 23 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | wu0olraudhmga2svshmi0aw4.gif |
Supplier Communication Details
| Quality Head Email ID | quality@sagarsprings.com |
| Plant Head/CEO Email ID | sagrarsprings@gmail.com |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
13000
|
0
|
0
|
5000
|
0
|
18000
|
| Check Qty |
13000
|
0
|
0
|
5000
|
0
|
18000
|
| NG Qty |
23
|
0
|
0
|
0
|
0
|
23
|
| Scrap | 23 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Scrap |
3. Process Flow
| Process Flow Description |
|---|
| Coiling - Tempering - Grinding - Shot Peening - Tempering - Oiling - Final Inspection - Packing |
4. Process Details
| Process / Operation | Oiling |
| Outsource | No |
| Machine / Cell | Oiling Tray |
| Machine / Cell No. | Oiling |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | New operator | Senior operators working at all process stages | O |
| Method | Mix up at production line during material handling | Parts separately processes and moved to next process stage | O |
| Man | Untrained operator | Trained operators working at all process stages | O |
| Method | Mix up at Inspection table | Part wise samples collected, inspected, move samples to container and moved to oiling | O |
| Method | Mix up at oiling and packing | Similar looking parts being oiled & packed at same time | X |
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 | Sample pla |
7. Root Cause Analysis (Occurance)
| Why 1 | Mix up at oiling & packing |
| Why 2 | Other model springs mix up during oiling |
| Why 3 | Similar looking springs oiled and packed at same time |
| Why 4 | similar looking springs at same location for oiling |
| Why 5 | One oiling tray available for oiling similar looking springs |
| Root Cause (Occurance) | One oiling tray available for oiling similar looking springs |
Root Cause Analysis (Outflow)
| Why 1 | Mix up of other model springs |
| Why 2 | Mix up could not able to found during final inspection |
| Why 3 | Mix up occurred after final inspection |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Mix up occurred after final inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Three oiling trays arranged to oil similar looking springs and prevent mix up | SSPL | 30/06/2024 | 30/06/2024 | Completed |
| Outflow | After final inspection springs will be immediately oiled, packed and moved to dispatch. | SSPL | 30/06/2024 | 30/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No change |
| Inspection Method | Other |
| Other Inspection Method | Sampling inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | sample pla |
10. Evidance of Countermeasure
| Occurance (Before) |
One oiling tray available for oiling all models of rebound springs (similar looking springs) caused mix up 885_Occurance_Before.pptx |
| Occurance (After) |
Two more oiling trays arranged to oil similar looking springs separately and prevent mix up 885_Occurance_After.pptx |
| Outflow (Before) |
After final inspection oiling and packing as per packing plan 885_Outflow_Before.pptx |
| Outflow (After) |
After final inspection immediately oiling, packing without delay to prevent mix up 885_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Actions applicable for all rebound springs |
12. Document Review
| Documents | PFMEA |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Reviewed next two lots found ok |