QFR No - 8000885867
Defect Details
| NC No. | 8000885867 |
| NC Date | 07/08/2024 |
| NC Submission Date | |
| Part No. | 550DZ05202 |
| Part Name | FORK BOLT :PRFH-006 |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-BURR AT GROOVE WIDTH |
1. Problem Description
| Defect Description | Fork Bolt Groove ID Burr |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 50 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | 0sppjw30xuq1bpksvo5u13ck.jpg |
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 |
8000
|
0
|
0
|
2000
|
5000
|
15000
|
| Check Qty |
8000
|
0
|
0
|
2000
|
5000
|
15000
|
| NG Qty |
50
|
0
|
0
|
0
|
9
|
59
|
| Scrap | 0 |
| Rework | 59 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregated all pipeline material at customer end and sharp end |
3. Process Flow
| Process Flow Description |
|---|
| RM incoming-Parting and drilling-Tip grinding-CNC 1st -pre thread drilling and chamfering-OD grinding-Thread rolling-Tapping M10-plating - final inspection-PDI-Packing and forwarding |
4. Process Details
| Process / Operation | Plating |
| Outsource | Yes |
| Machine / Cell | Plating |
| Machine / Cell No. | Plating Plant |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | New operator | No new operator | O |
| Man | Unskilled operator | Operator skilled as per skill matrix | O |
| Material | Material grade change | Material grade is as per requirement | O |
| Machine | Burr particle deposited in plating tank | Bur particle found in plating tank | X |
| Machine | Plating process parameter not as per specification | Plating process parameter is as per specification | O |
| Method | Plating tank cleaning method not followed | Plating tank cleaning method followed as per control plan | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Burr observed in the groove |
| Why 2 | Burr stick on part during process |
| Why 3 | Burr from dangler stick into groove |
| Why 4 | Barrel dangler not clean |
| Why 5 | Barrel dangler cleaning frequency once in week |
| Root Cause (Occurance) | Barrel dangler cleaning frequency once in week |
Root Cause Analysis (Outflow)
| Why 1 | Burr observed in the groove |
| Why 2 | Skip from inspection |
| Why 3 | Inspection size is less |
| Why 4 | Inspection size was 10 nos per lot |
| Why 5 | |
| Root Cause (Outflow) | Inspection size was 10 nos per lot |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Barrel dangler frequency changed from one week to Daily basis | Mr.Pradip Bhagwat | 10/08/2024 | 10/08/2024 | Completed |
| Outflow | Inspection size increased to 20 nos per lot | Mr. Pradip Bhagwat | 10/08/2024 | 10/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Dangler Barrel cleaning frequency changed. |
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Dangler not clean 1001_Occurance_Before.jpeg |
| Occurance (After) |
Dangler clean 1001_Occurance_After.jpeg |
| Outflow (Before) |
Inspection frequency is 10 nos per lot 1001_Outflow_Before.jpg |
| Outflow (After) |
Inspection frequency ins 20nos per lot 1001_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Barrels |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | OK |