QFR No - 8000882628
Defect Details
| NC No. | 8000882628 |
| NC Date | 15/07/2024 |
| NC Submission Date | |
| Part No. | F2FA11933B |
| Part Name | FORK PIPE MACHINED - J1D |
| Supplier Name & Code | 101030-TUBE INVESTMENTS OF INDIA LTD |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-THREADING NG |
1. Problem Description
| Defect Description | THREADING NG |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 11 |
| 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 |
400
|
0
|
0
|
0
|
0
|
400
|
| Check Qty |
400
|
0
|
0
|
0
|
0
|
400
|
| NG Qty |
11
|
0
|
0
|
0
|
0
|
11
|
| Scrap | 11 |
| 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 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | No step wise offset given & verified it`s impact to achieve the product characteristics | Wrong off set at time of set up | X |
| Method | Inspection on a sampling basis | Inspection on a sampling basis which is not adequate for detection | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 13 Nos/500 |
7. Root Cause Analysis (Occurance)
| Why 1 | Threading NG - Threading Minor Dia observed under size. |
| Why 2 | Excess Material removal during machining Cut for threading Minor Dia |
| Why 3 | During the Machining setup geometric parameter setting not proper |
| Why 4 | The wrong offset value was put during the setup. |
| Why 5 | The CNC Program did not have Offest value interlocking to give threading offset. & hence offset could be given from 10 microns to 0.2 mm. |
| Root Cause (Occurance) | The CNC Program did not have Offest value interlocking to give threading offset. & hence offset could be given from 10 microns to 0.2 mm. |
Root Cause Analysis (Outflow)
| Why 1 | Not detected during the final inspection |
| Why 2 | Inspection on a sampling basis which is not adequate for detection |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspection on a sampling basis which is not adequate for detection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Threading Offset Value has been locked in the CNC Program for 50 microns so that more than 50 micron offset cannot be given. | Mr. Rathod KS | 16/07/2024 | 16/07/2024 | Completed |
| Outflow | Sampling Inspection Qty. Doubled from 13 Nos/500 Nos. . to 26 Nos./500 Nos. | Mr. Dethe SS | 16/07/2024 | 16/07/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Sampling Inspection Qty. Doubled from 13 Nos/500 Nos. to 26 Nos./500 Nos. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 26/500 Nos |
10. Evidance of Countermeasure
| Occurance (Before) |
Before: The CNC Program did not have Offset value interlocking to give threading offset. & hence offset could be given from 10 microns to 0.2 mm. 940_Occurance_Before.pdf |
| Occurance (After) |
After: Threading Offset Value has been locked in the CNC Program for 50 microns so that more than 50-micron offset cannot be given. 940_Occurance_After.pdf |
| Outflow (Before) |
Sampling Inspection Qty. 13 Nos/500 Nos. Not Adhequete 940_Outflow_Before.pdf |
| Outflow (After) |
Sampling Inspection Qty. Doubled from 13 Nos/500 Nos. . to 26 Nos./500 Nos 940_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Models |
12. Document Review
| Documents | WISOP, InspCheckSheet |
| Specify Other Document | WI |
13. Effectiveness Of Action
| Reviewed Quantity | 214 |
| Reason for submission | OK |