QFR No - 8000881730
Defect Details
| NC No. | 8000881730 |
| NC Date | 08/07/2024 |
| NC Submission Date | |
| Part No. | F20519007B |
| Part Name | UNDER BRACKET ASSEMBLY H107B PHASE 1 |
| Supplier Name & Code | 100073-SINGLA FORGING (P) LTD |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | THREADING NOT OK-Step observed |
1. Problem Description
| Defect Description | THREADING NOT OK-Step observed |
| Detection Stage | Customer End |
| Problem Severity | Fitment |
| NG Quantity | 5 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@singlaforging.in |
| Plant Head/CEO Email ID | quality@singlaforging.in |
| MD Email ID | jain@singlaforging.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
100
|
500
|
0
|
0
|
0
|
600
|
| Check Qty |
100
|
500
|
0
|
0
|
0
|
600
|
| NG Qty |
70
|
370
|
0
|
0
|
0
|
440
|
| Scrap | 0 |
| Rework | 440 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% THREADING DIE ANSWER IN THE THREAD TILL THE GROOVE END ,WHICH AVAILABLE BELOW THE THREAD |
3. Process Flow
| Process Flow Description |
|---|
| STEERING SHAFT PFD:- 10-RECEIPT OF MATERIAL 20-RECEIPT INSPECTION , 30-STORAGE , 40-DMC OPERATION, 50-CNC TURNING 1ST ,60-BUSH PRESSING, 70-HOLE BUSH WELDING, 80-CNC TURNING 2ND , 90-CNC TURNING 3RD, 100-CNC TURNING 4TH |
4. Process Details
| Process / Operation | 100-CNC TURNING |
| Outsource | No |
| Machine / Cell | CNC TURNING |
| Machine / Cell No. | CNC |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Unskilled operator.inspector | skill matrix | O |
| Machine | wrong correction in machine eprogram | thraed length 21.5 is mention in the machjine program and drawing requirement 21.5-1.0 mm | O |
| Method | Limitation of drawing | during verification of the drawing ,it observed that groove dia is more than the thread minor dia | X |
| Machine | Incomplete operation | Program completion logic is available at machine as part will not de-clamp without complete of opera | O |
| Machine | wrong offset | offset value locked in 0.005mm | O |
| Method | inspection frequecy not followed | 100% inspection done by TRG | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Matting part mot answering on the thread till the groove end |
| Why 2 | Groove diameter is more than the thread minor diameter |
| Why 3 | Specification given as per the drawing |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Groove diameter is more by the thread minor diameter by which matting part not answering till groove end |
Root Cause Analysis (Outflow)
| Why 1 | Part not detected in the final inspection stage |
| Why 2 | TRG gauge answering till the thread end. |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | NO |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Customer drawing need to revise either for thread length or for the groove depth. | ETL | 10/08/2024 | Inprocess | |
| Occurance | Thread length raised by the 1mm in the machine program by which minor diameter profile machined in the groove & gauge or matting part answer till the groove end. effective date 25.06.2024 | QA | 01/08/2024 | 01/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No change point |
| 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) |
Machine program in which thread length was 21.5mm 925_Occurance_Before.jpeg |
| Occurance (After) |
Machine program in which thread length is 22.5mm,which is out of the drawing but meeting the customer requirement. 925_Occurance_After.jpeg |
| Outflow (Before) |
TRG 925_Outflow_Before.jpeg |
| Outflow (After) |
TRG 925_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NO |
12. Document Review
| Documents | Drawing, ControlPlan |
| Specify Other Document | Need revise Cust Drg |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |