QFR No - 8000884335
Defect Details
| NC No. | 8000884335 |
| NC Date | 26/07/2024 |
| NC Submission Date | |
| Part No. | F2DZ00912O |
| Part Name | FORK BOLT - K8 |
| Supplier Name & Code | 101263-SINGLA PRECISION SCREWS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-OD O/S FITMENT NG |
1. Problem Description
| Defect Description | OD O/S |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 11 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@singlaprecision.com |
| Plant Head/CEO Email ID | quality@singlaprecision.com |
| MD Email ID | aditya@singlaprecision.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
540
|
0
|
0
|
2000
|
2000
|
4540
|
| Check Qty |
540
|
0
|
0
|
2000
|
2000
|
4540
|
| NG Qty |
11
|
0
|
0
|
0
|
0
|
11
|
| Scrap | 11 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| We Checked 100% material lying at Various stage |
3. Process Flow
| Process Flow Description |
|---|
| Raw material +Part off +Drilling +Punching +Drilling +Tapping +CNC Machine +Rolling +Re-Tapping +Finish +Final Inspection +Packing |
4. Process Details
| Process / Operation | Punching |
| Outsource | Yes |
| Machine / Cell | Punching |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Material to Swell in Punching Process | Validation And Found NG | X |
| Material | RM GRADE AND SIZE NOT OK | VALIDATION ANF FOUND OK | O |
| Man | UNAWARENESS OF OPERATOR | VALIDATION AND FOUND OPERATOR SKILL LEVEL LOW | X |
| Tool | Punching tool wear out | Validation and Found OK | O |
| Method | Forging Part checking gauge not effective | Validation And Found NG | 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 | sampling |
7. Root Cause Analysis (Occurance)
| Why 1 | NOT AS PER SPECIFICATION-OD |
| Why 2 | Material to swell in Punching process |
| Why 3 | After Punching Process not CLG Process Add |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | CLG operation not add after Punching process |
Root Cause Analysis (Outflow)
| Why 1 | NOT AS PER SPECIFICATION-OD |
| Why 2 | Inspection Plan was not Effective |
| Why 3 | final inspection standard checking Frequency change 100% Gauge implements |
| Why 4 | As per sampling Plan part checking in final inspection |
| Why 5 | Ng part skipped from inspection and machine |
| Root Cause (Outflow) | final inspection standard checking Frequency change 100% Gauge implements |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | final inspection standard checking Frequency change 100% Gauge implements | Mr Ganesh Maurya | 31/07/2024 | 01/08/2024 | Completed |
| Occurance | CLG operation not add after Punching process | Mr Ganesh Maurya | 31/07/2024 | 01/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | final inspection standard checking Frequency change OD -100% Gauge implements |
| 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) |
CLG operation not add after Punching process 975_Occurance_Before.jpeg |
| Occurance (After) |
CLG operation add after Punching process 975_Occurance_After.jpeg |
| Outflow (Before) |
Final Inspection standards as per sampling plan 975_Outflow_Before.jpeg |
| Outflow (After) |
Final Inspection standards 100% OD Dia checked 975_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | clg machine -01 |
12. Document Review
| Documents | Drawing |
| Specify Other Document | PFMEA ,Final insp St |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | 5. Problem Analysis - Need all 4M 7. Root Cause Analysis (Occurance & Outflow) - Not clear |