QFR No - 8000884592
Defect Details
| NC No. | 8000884592 |
| NC Date | 30/07/2024 |
| NC Submission Date | |
| Part No. | 550DZ05202 |
| Part Name | FORK BOLT :PRFH-006 |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | THREADING NOT OK-MINOR DIA GO NOT ANSWERING |
1. Problem Description
| Defect Description | FORK BOLT M10 THREAD MINOR DIA PLUG GAUGE GO NOT ANSWERING |
| Detection Stage | Receipt |
| Problem Severity | Safety |
| NG Quantity | 139 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@apw3.co.in |
| 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 |
3000
|
0
|
0
|
2500
|
3500
|
9000
|
| Check Qty |
3000
|
0
|
0
|
2500
|
3500
|
9000
|
| NG Qty |
139
|
0
|
0
|
5
|
3
|
147
|
| Scrap | 147 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done immediately for all suspected material of pipeline. |
3. Process Flow
| Process Flow Description |
|---|
| RM incoming-Parting and drilling-Tipm grinding-CNC 1st-Pre thread drilling and tapping-OD grinding - thread rolling-Tapping -Plating-final inspection-Pre dispatch inspection-packing and forwarding |
4. Process Details
| Process / Operation | Tapping |
| Outsource | No |
| Machine / Cell | Tapping |
| Machine / Cell No. | Tapping |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | New operator | Experienced operator is working | O |
| Man | Unskilled operator | Operator available as per skill matrix. | O |
| Method | Wrong setting | Setting done ok | O |
| Tool | Wrong tool | Tool found ok | O |
| Machine | Process parameter change | found as per specification | O |
| Method | Checking Method | Verified and found ok | O |
| Machine | Plating thickness | found plating thickness oversize | X |
| Material | Material grade change | found as per specification | O |
| Material | Material hardness | as per specification found | O |
| Tool | Wear out | found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | M10 THREAD MINOR DIA PLUG GAUGE GO NOT ANSWERING |
| Why 2 | Minor Dia Undersize |
| Why 3 | Undersize by 20micron |
| Why 4 | Found Excess of plating |
| Why 5 | Barrel time increased due to manual dependency |
| Root Cause (Occurance) | Barrel time increased due to manual dependency |
Root Cause Analysis (Outflow)
| Why 1 | M10 THREAD MINOR DIA PLUG GAUGE GO NOT ANSWERING |
| Why 2 | Skip from inspection |
| Why 3 | Inspection frequency is less |
| Why 4 | Inspection frequency is 10 nos per lot |
| Why 5 | |
| Root Cause (Outflow) | Inspection frequency is 10 nos per lot |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Started production on Auto line to avoid Excess of plating due to timing | Mr. Pradeep Bhagwat | 14/08/2024 | 14/08/2024 | Completed |
| Outflow | Inspection frequency was increased to 20 nos per lot, also started 100% of inspection before dispatched | Mr. Omkar Bhange | 14/08/2024 | 14/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection frequency was increased to 20 nos per lot, |
| 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) |
Barrel time increased due to manual dependency 989_Occurance_Before.jpeg |
| Occurance (After) |
Started production on Auto line 989_Occurance_After.jpeg |
| Outflow (Before) |
Inspection frequency is 10 nos per lot and sampling inspection. 989_Outflow_Before.jpg |
| Outflow (After) |
Inspection frequency is 20 nos per lot also started 100% gauge inspection before dispatch. 989_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | reviewed next 2 lots found ok |