QFR No - 8000882706
Defect Details
| NC No. | 8000882706 |
| NC Date | 17/07/2024 |
| NC Submission Date | |
| Part No. | F2DZ04512B |
| Part Name | SCREW CAP/FORK BOLT ABWA ADJUSTABLE |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | DIMETER UNDERSIZE-7+0.1 UINDER SIZE |
1. Problem Description
| Defect Description | 7+0.1 dimension found under size by up to 0.2 mm |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 118 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@sharp-engineers.com |
| Plant Head/CEO Email ID | kurund.ma@sharp-engineers.com |
| MD Email ID | urkhandelwal@sharp-engineers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
450
|
0
|
0
|
1200
|
0
|
1650
|
| Check Qty |
450
|
0
|
0
|
1200
|
0
|
1650
|
| NG Qty |
118
|
0
|
0
|
28
|
0
|
146
|
| Scrap | 146 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Pipline material segregated at Customer and our end |
3. Process Flow
| Process Flow Description |
|---|
| RM incoming Inspection |
4. Process Details
| Process / Operation | CNC |
| Outsource | No |
| Machine / Cell | CNC |
| Machine / Cell No. | CNC |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Insert broken | No insert broken | O |
| Method | Fixture not clesn properly | Fixture cleaned after every cycle regardi ng Work Instruction also displayed at Machine stage | O |
| Man | New manpower | Manpower available as per skill matrix | O |
| Man | Unskill operator | Skill operator available | O |
| Man | Wrong setting done by operator | Setting done ok, also Setup approval report evident | O |
| Machine | power cut | no power cut | O |
| Tool | Insert wear out | No insert wear out | O |
| Method | Insert not change at defined frequency | As per tool history card its obeserved tool changed at defined frequency | O |
| Method | Part not validated after replacement of insert | Part not validated after replacement of insert | X |
| Tool | Tool Change | No any tool changed | O |
| Material | RM change | RM found as pr requirement | O |
| Machine | Machine changed | No machine change | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Dimension 7 undersized |
| Why 2 | Dimension 7 +0.2/+0.1 observed 6.95 |
| Why 3 | Insert changed |
| Why 4 | Insert life over |
| Why 5 | verification not done after replacement of insert coz dependency on operator. |
| Root Cause (Occurance) | Part not validated after replacement of insert by operator |
Root Cause Analysis (Outflow)
| Why 1 | Dimension 7 undersized |
| Why 2 | Skip from inspection |
| Why 3 | No checkpoint at final inspection |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No checkpoint at final inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Checkpoint added in Final inspection and verification started at PDI stage | Omkar Bhange | 31/07/2024 | 31/07/2024 | Completed |
| Outflow | Part verification started by Supervisor and Inprocess engineer after replacement of Insert. | Ingole and Yogesh chavan | 30/07/2024 | 31/07/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Verification started by Supervisor and Inprocess engineer |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
10. Evidance of Countermeasure
| Occurance (Before) |
Operator dependency for part verification after replacement of insert 944_Occurance_Before.jpg |
| Occurance (After) |
On job training given to Production supervisor and Inprocess engineer for verification of part after replacement of insert 944_Occurance_After.jpeg |
| Outflow (Before) |
No check point in final inspection 944_Outflow_Before.jpg |
| Outflow (After) |
Check point added in Final inspection also verification point added in PDI report 944_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | For all machine |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | after correction issue not observed. |