QFR No - 8000882493
Defect Details
| NC No. | 8000882493 |
| NC Date | 14/07/2024 |
| NC Submission Date | |
| Part No. | F2FA10933M |
| Part Name | FORK PIPE MACHINED - J1A |
| Supplier Name & Code | 100576-SANGKAJ BRIGHT WIRES PVT LTD |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-DU BUSH OD O/S |
1. Problem Description
| Defect Description | DU BUSH OD O/S |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 53 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | brightwire.qa@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 |
3500
|
0
|
0
|
2500
|
1500
|
7500
|
| Check Qty |
3500
|
0
|
0
|
2500
|
1500
|
7500
|
| NG Qty |
53
|
0
|
0
|
0
|
0
|
53
|
| Scrap | 53 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1) At ETL end verified 3500 Nos & 53 nos found not ok. 2) At SBWPL end verify 4000 nos & all part found ok. 3) For ok parts provided 100 % Verification identification marking on DU bush OD. |
3. Process Flow
| Process Flow Description |
|---|
| Receipt Of Material - Inward Inspection - CNC 1st Setup - CNC 2nd Setup - Drilling - Final Inspection - Air Cleaning - Dispatch |
4. Process Details
| Process / Operation | CNC 2nd Setup |
| Outsource | No |
| Machine / Cell | Machining |
| Machine / Cell No. | Fork Pipe Machining |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Material Hardness not ok | Verified found ok | O |
| Machine | Wear Offset lock | Verified found not ok | X |
| Method | Loading & Unloading | Verified Found OK | O |
| Man | Operator New | Verified found not ok | X |
| Tool | Tool holder loose | Verified Found Ok | O |
| Machine | Spindle Run out | Verified found ok | 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 | 10 nos |
7. Root Cause Analysis (Occurance)
| Why 1 | DU Bush OD Oversize |
| Why 2 | DU Bush OD At lower side |
| Why 3 | At the time of correction operator take offset 0.04. reading get higher size by 0.01 |
| Why 4 | Wrong offset given by operator |
| Why 5 | Wear offset not lock in cnc machine in 0.05mm |
| Root Cause (Occurance) | Wear offset not lock in cnc machine in 0.05mm |
Root Cause Analysis (Outflow)
| Why 1 | DU Bush OD Oversize |
| Why 2 | inspection skipped by Operator |
| Why 3 | inspection done on sampling basis. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | inspection done on sampling basis. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | `For ok parts provided 100 % Verification identification marking on DU Bush OD. | Mr. Nitin Puri | 14/07/2024 | 14/07/2024 | Completed |
| Occurance | Provide On job Training and awareness given to all inspectors and CNC Operator for DU Bush OD oversize & its importance | Mr. Barik & Nitin Puri | 14/07/2024 | 14/07/2024 | Completed |
| Occurance | Wear Offset lock by 0.03mm | Mr. Barik | 15/07/2024 | 15/07/2024 | Completed |
| Outflow | Display the OPL | Mr. Mukesh Rathod & Manoj Pathe | 14/07/2024 | 14/07/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | started 100% Inspection at final inspection stage only for 10 days. after 10 days we have started the sampling basis 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) |
Wear Offset lock in 0.05mm 936_Occurance_Before.jpg |
| Occurance (After) |
Wear Offset lock in 0.01mm 936_Occurance_After.jpg |
| Outflow (Before) |
Identification not provided after inspection 936_Outflow_Before.jpg |
| Outflow (After) |
Identification mark provided after inspection 936_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All model |
12. Document Review
| Documents | WISOP |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 144 |
| Reason for submission | Why Wear offset not consider 0.010mm In future it will repeat So reverify for wear offset 0.010mm against 0.03mm |