QFR No - 8000880725
Defect Details
| NC No. | 8000880725 |
| NC Date | 02/07/2024 |
| NC Submission Date | |
| Part No. | F2FA10933M |
| Part Name | FORK PIPE MACHINED - J1A |
| Supplier Name & Code | 101030-TUBE INVESTMENTS OF INDIA LTD |
| 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 | 12 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | AmitVD@tii.murugappa.com |
| Plant Head/CEO Email ID | guptaajay@tii.murugappa.com |
| MD Email ID | mukeshahuja@tii.murugappa.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
0
|
0
|
0
|
1500
|
3500
|
| Check Qty |
2000
|
0
|
0
|
0
|
1500
|
3500
|
| NG Qty |
12
|
0
|
0
|
0
|
12
|
24
|
| Scrap | 12 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Stock available at ETL end & Inhouse checked for the Threading Parameter |
3. Process Flow
| Process Flow Description |
|---|
| Raw Material Inspection- Machining (Cualking & Threading)-Drilling-Oiling-Final Inspection-Dispatch |
4. Process Details
| Process / Operation | Machining |
| Outsource | No |
| Machine / Cell | CNC Machine Cell |
| Machine / Cell No. | Machine No.22/23 &14 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | No Inspection for Length Parameter | Inspection on the Sampling Basis | X |
| Machine | Stopper Condtion Not OK | The uneven resting surface of the stopper | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | Sampling |
7. Root Cause Analysis (Occurance)
| Why 1 | Total Length Observed Undersize |
| Why 2 | Tube end face not resting properly on Stopper Surface |
| Why 3 | The uneven resting surface of the stopper |
| Why 4 | During Mass production resting surface of the stopper wears out |
| Why 5 | The current Stopper, material used was MS & Not enough which caused the stopper wear out |
| Root Cause (Occurance) | The current Stopper, material used was MS & Not enough which caused the stopper wear out |
Root Cause Analysis (Outflow)
| Why 1 | Not Detected during the Final Inspection & PDIR Why 2 |
| Why 2 | Inspection on the Sampling Basis |
| Why 3 | No Length Inspection gauge is available for the 100 % Inspection |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No Length Inspection gauge is available for the 100 % Inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | The Carbide material was used for the new stopper & made Properly hard ?50 to 65 HB ? & to prevent loose burr from sticking to the stopper, Also Provision was made for the coolant to come out from the stopper. | Mr. Rathod KS | 03/07/2024 | 03/07/2024 | Completed |
| Outflow | Length Gauge added for the 100% Inspection | Mr. Dethe SS | 03/07/2024 | 03/07/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Length Inspection Gauge Added for the 100 % Inspection |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
10. Evidance of Countermeasure
| Occurance (Before) |
The current Stopper, material used was MS & Not enough which caused the stopper to wear out 901_Occurance_Before.pdf |
| Occurance (After) |
The Carbide material was used for the new stopper & made Properly hard ?50 to 65 HB ? & to prevent loose burr from sticking
to the stopper, Also Provision was made for the coolant to come out from the stopper. 901_Occurance_After.pdf |
| Outflow (Before) |
Before: No 100 % Inspection on Length Gauge 901_Outflow_Before.pdf |
| Outflow (After) |
After: 100 % Inspection Started by Using Length Inspection Gauge 901_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Model |
12. Document Review
| Documents | WISOP, InspCheckSheet |
| Specify Other Document | WI |
13. Effectiveness Of Action
| Reviewed Quantity | 120 |
| Reason for submission | Ok |