QFR No - 8000879789
Defect Details
| NC No. | 8000879789 |
| 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 | BEND- |
1. Problem Description
| Defect Description | Rebound Spring bend issue . |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 2 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@sagarsprings.com |
| Plant Head/CEO Email ID | sagarsprings@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 |
15000
|
0
|
0
|
5000
|
0
|
20000
|
| Check Qty |
15000
|
0
|
0
|
5000
|
0
|
20000
|
| NG Qty |
2
|
0
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Scrap |
3. Process Flow
| Process Flow Description |
|---|
| Coiling - Tempering - Grinding - Shot Peening - Tempering - Oiling - Packing |
4. Process Details
| Process / Operation | Material Handling / Movement between operations |
| Outsource | No |
| Machine / Cell | Material Handling / Movement between operations |
| Machine / Cell No. | Trolley |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Untrained operator | Trained operators working at all process stages | O |
| Method | Spring bend during material handling | Material handled / moved in trolleys and potential chances of bend | X |
| Man | New operator | Experienced operators working at all process atages | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Sampling inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | sample pla |
7. Root Cause Analysis (Occurance)
| Why 1 | Spring bend during material handling |
| Why 2 | Material handling in trolleys caused bend |
| Why 3 | During material unloading springs fallen on ground and trolly wheel passed on spring and same springs got mixed up with lot |
| Why 4 | Material handling trolley design constrain |
| Why 5 | |
| Root Cause (Occurance) | Material handling trolley design constrain |
Root Cause Analysis (Outflow)
| Why 1 | Spring Bend |
| Why 2 | Spring bend problem could not able to detect at final inspection |
| Why 3 | Sampling inspection |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Sampling inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | New model trolley designed to handle / move rebound springs to prevent bend | SSPL | 30/06/2024 | 30/06/2024 | Completed |
| Outflow | Visual inspection will be done after final inspection for free from bend & before oiling and packing | SSPL | 30/06/2024 | 30/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Visual Inspection |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% Visua |
10. Evidance of Countermeasure
| Occurance (Before) |
Material handling trolley design constraint causing spring bend during unloading springs 886_Occurance_Before.pptx |
| Occurance (After) |
Trolley design modified to prevent spring bend issue 886_Occurance_After.pptx |
| Outflow (Before) |
At final Inspection sampling inspection followed caused non detection of spring bend 886_Outflow_Before.pptx |
| Outflow (After) |
After final inspection visual inspection before coiling to detect spring bend issue 886_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Action applicable for all rebound springs |
12. Document Review
| Documents | PFMEA |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 10000 |
| Reason for submission | Reviewed next two lots found ok no issue . |