QFR No - 8000880715
Defect Details
| NC No. | 8000880715 |
| NC Date | 02/07/2024 |
| NC Submission Date | |
| Part No. | 550FA19533 |
| Part Name | FORK PIPE MACHINED K8 |
| Supplier Name & Code | 101222-SANGKAJ ENGINEERING PVT LTD- U |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-SHORT LENGTH |
1. Problem Description
| Defect Description | SHORT LENGTH |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 26 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | aslam@sangkaj.com |
| Plant Head/CEO Email ID | pardenshinr@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 |
2000
|
0
|
0
|
100
|
0
|
2100
|
| Check Qty |
2000
|
0
|
0
|
100
|
0
|
2100
|
| NG Qty |
26
|
0
|
0
|
0
|
0
|
26
|
| Scrap | 26 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done at ETL-K228, and also at M/S Sangkaj engineering. |
3. Process Flow
| Process Flow Description |
|---|
| Tube Inward - Induction hardening - CNC1st - CNC 2nd - Drilling - Visual inspection - bundling - Dispatch |
4. Process Details
| Process / Operation | CNC 2nd setup |
| Outsource | No |
| Machine / Cell | CNC machine |
| Machine / Cell No. | CNC machine |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Loading of component not as per defined method | Component loading as per specified method | X |
| Material | Rework material , mixed up with ok material | Separate bins are provided for R/W and OK material | X |
| Machine | Stopper can be loose | Stopper observed loose during running the machine | O |
| Man | Operator not followed Inspection sequence | Program is provided to control the operation sequence. | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 500:10 |
7. Root Cause Analysis (Occurance)
| Why 1 | Machine stopper nut position shifted. |
| Why 2 | Stopper provided nut observed loose. |
| Why 3 | Nut couldn`t sustain the load during running the machine. |
| Why 4 | Single nut is provided to the stopper. |
| Why 5 | |
| Root Cause (Occurance) | Single Nut provided to the stopper. |
Root Cause Analysis (Outflow)
| Why 1 | Total length observed oversize. |
| Why 2 | Not detected into the final inspection |
| Why 3 | Checking frequency got less. (500:10) |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Checking frequency got less. (500:10) |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | OPL is provided on machine. | Mr Krushna Phuke | 24/07/2024 | 02/07/2024 | Completed |
| Outflow | Inspection frequency increased by 500:20 | Mr Amol Tali | 24/07/2024 | 02/07/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Checking frequency is increased by 500:20 |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 500:20 |
10. Evidance of Countermeasure
| Occurance (Before) |
Single Nut provided to stopper 898_Occurance_Before.pdf |
| Occurance (After) |
Double Nut provided to stopper. 898_Occurance_After.pdf |
| Outflow (Before) |
Checking frequency got less 898_Outflow_Before.pdf |
| Outflow (After) |
Checking Frequency increased 898_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Same department/ Machine Cell |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |