QFR No - 8000880024
Defect Details
| NC No. | 8000880024 |
| NC Date | 26/06/2024 |
| NC Submission Date | |
| Part No. | 080FA04433 |
| Part Name | FORK PIPE MACHINED - CT100 |
| Supplier Name & Code | 101223-SANGKAJ BRIGHT WIRES PRIVATE L |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | THREADING NOT OK- |
1. Problem Description
| Defect Description | CT 100 FORK PIPE MACHINED THREADING ISSUE (THREAD PLUG GAUGE GO NOT QUALIFY ) |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 165 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | mayursurese11@gmail.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 |
0
|
0
|
0
|
2000
|
1000
|
3000
|
| Check Qty |
0
|
0
|
0
|
2000
|
1000
|
3000
|
| NG Qty |
0
|
0
|
0
|
1
|
0
|
1
|
| Scrap | 0 |
| Rework | 1 |
| Under Deviation | 0 |
| Containment Action |
|---|
| LAST 2 YEARS PROCESS REJECTION GIVEN BY K228 |
3. Process Flow
| Process Flow Description |
|---|
| Cnc 1st-Cnc 2nd-Drill-Final Inspection -Dispatch |
4. Process Details
| Process / Operation | CNC 1ST SIDE |
| Outsource | No |
| Machine / Cell | MACHINE |
| Machine / Cell No. | 1,2,3,4,5 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | M26X1P-6H Gauge not pass | Wrong offset given by operator | 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 | 5nos |
7. Root Cause Analysis (Occurance)
| Why 1 | M2X1P-6H Gauge not answered |
| Why 2 | Insert wear out |
| Why 3 | After changing new insert At The Time of correction operator taken 0.3mm offset instead of 0.03mm. |
| Why 4 | Wrong offset given by operators. |
| Why 5 | Wear offset not lock in programm |
| Root Cause (Occurance) | Wear offset not lock in programm |
Root Cause Analysis (Outflow)
| Why 1 | M26X1P-6H Thread not answered |
| Why 2 | Inspection as a sampling basis |
| Why 3 | Inspection Done On Sampling Basis. (5 Nos / Lot) |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspection Done On Sampling Basis. (5 Nos / Lot) |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Wear Offset locked By 0.03mm In CNC Machine. | Mayur | 28/06/2024 | 29/06/2024 | Completed |
| Outflow | Started 100% Inspection At Machining Stage With The Help Of TPG GO and NOGO. | Pratap Behra | 28/06/2024 | 29/06/2024 | Completed |
| Occurance | Too life decided & Lock in CNC Machine. | Mayur | 28/06/2024 | 29/06/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | 100% inspection at CNC Stage |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 50 |
10. Evidance of Countermeasure
| Occurance (Before) |
NO INTERLOCK CNC MC 893_Occurance_Before.jpg |
| Occurance (After) |
0.03 mm interlock 893_Occurance_After.png |
| Outflow (Before) |
Sampling basis inspection 893_Outflow_Before.png |
| Outflow (After) |
Sampling basic inspection but 50 nos check every lot & OPL dispalyed FID 893_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | K3 FORK PIPE,K17 FORK PIPE,ATHER,Ampere |
12. Document Review
| Documents | WISOP, InspCheckSheet |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 2000 |
| Reason for submission | Reviewed next two lots found ok |