QFR No - 8000881725
Defect Details
| NC No. | 8000881725 |
| NC Date | 08/07/2024 |
| NC Submission Date | |
| Part No. | F2LG07102B |
| Part Name | SEAT PIPE - J1D |
| Supplier Name & Code | 101222-SANGKAJ ENGINEERING PVT LTD- U |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | THREADING MISSING-WITHOUT THREADING |
1. Problem Description
| Defect Description | Thread missing |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | aslam@sangkaj.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 |
1000
|
0
|
0
|
500
|
500
|
2000
|
| Check Qty |
1000
|
0
|
0
|
500
|
500
|
2000
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation of pipeline material, FG material, and Customer end |
3. Process Flow
| Process Flow Description |
|---|
| 10.RM Inspection; 20.Parting off and chamfering; 30.Weighing and moly powder application; 40.Draw forging; 50.Head Forging; 60.Rough Grinding; 70A. Collar Machining; 70B. Total length facing, Drilling & Tapping; 80.Hole piercing; 90 DF and Compression hole chamfering; 100.ID Cleaning & Deburring; 110.Finish Grinding; 120.Ultrasonic Cleaning; 130. Final Inspection; 140.Oiling; 150.Packing and storage. |
4. Process Details
| Process / Operation | 70B |
| Outsource | No |
| Machine / Cell | CDL CNC |
| Machine / Cell No. | CDL CNC-01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Material grade not ok | Material grade found OK. | O |
| Man | Machine operator/Final inspector not as per skill materix | Machine operator & Final inspector found as per skill matrix | O |
| Tool | Wrong size grade tap used | Tapping tool found ok grade with Ok size | O |
| Method | Due to power off Operation not completed | Due to power of Threading operation not completed/missing | X |
| Machine | PM not as per plan | PM found as per plan | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
7. Root Cause Analysis (Occurance)
| Why 1 | Threading missing part produced |
| Why 2 | Threading operation not completed |
| Why 3 | Programmed on CNC machine for tapping not executed |
| Why 4 | Incomplete operation due to power off in running condition. . |
| Why 5 | |
| Root Cause (Occurance) | Incomplete operation due to power off in running condition. . |
Root Cause Analysis (Outflow)
| Why 1 | Threading missing part found at customer end |
| Why 2 | Threading missing part not detected/outflows |
| Why 3 | Detected part mixup in OK parts |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Threading missing part outflows due to mixup |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | In Work instruction add checkpoint for inspection of all parameter after power off. | Mr.Irfan | 07/08/2024 | 06/08/2024 | Completed |
| Outflow | Red paint on head side for threading missing / operation missing part (Add in Work instruction ) | Mr.Irfan | 07/08/2024 | 06/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % inspection with threading side blue color dot. |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
10. Evidance of Countermeasure
| Occurance (Before) |
NO instruction point for machine after power off 922_Occurance_Before.jpg |
| Occurance (After) |
Instruction added in Work instruction for Checking all parameters after power off 922_Occurance_After.jpg |
| Outflow (Before) |
Operation missing/threading missing part no special treatment 922_Outflow_Before.jpg |
| Outflow (After) |
Red spray paint apply on head for operation missing/thread missing part instruction added in WI 922_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | WISOP |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |