QFR No - 8000886626
Defect Details
| NC No. | 8000886626 |
| NC Date | 12/08/2024 |
| NC Submission Date | |
| Part No. | 520DZ01203 |
| Part Name | FORK BOLT NiCr PLATED ELIMIN. |
| Supplier Name & Code | 101263-SINGLA PRECISION SCREWS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | THREADING MISSING-WITHOUT THREADING |
1. Problem Description
| Defect Description | Threading Missing |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| 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 |
1000
|
2000
|
0
|
2000
|
3000
|
8000
|
| Check Qty |
1000
|
2000
|
0
|
2000
|
3000
|
8000
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 0 |
| Rework | 1 |
| Under Deviation | 0 |
| Containment Action |
|---|
| we are checked 100% material lying at various stage |
3. Process Flow
| Process Flow Description |
|---|
| Raw Material +Cutting + Annealing + Forging + CNC Turning + Head Facing + Counter + Buffing + Thread Rolling + Surface Treatment + Final Inspection + Packing |
4. Process Details
| Process / Operation | Thread Rolling |
| Outsource | No |
| Machine / Cell | Rolling |
| Machine / Cell No. | Rolling machine -02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | INSPECTION METHOD NOT EFFECTIVE | VALIDATION AND FOUND TRG NOT USE 100%IN MACHINE | X |
| Tool | DIE WEAROUT | VALIDATION AND FOUND DIE OK | O |
| Machine | ROLLING MACHINE PM NOT DONE AS PER PLAN | VALIDATION AND FOUND PM DONE | O |
| Man | UNAWARENESS OF OPERATOR | VALIDATION AND FOUND OPERATOR SKILL LEVEL LOW | X |
| Material | RM GRADE AND SIZE NOT OK | VALIDATION ANF FOUND OK | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | SAMPLING |
7. Root Cause Analysis (Occurance)
| Why 1 | THREADING MISSING-WITHOUT THREADING |
| Why 2 | The part skipped the threading process during production. |
| Why 3 | During Rolling Process 1 piece fell down from output bin |
| Why 4 | input and output material separate rack not provide in machine |
| Why 5 | material handling W.I not display on machine and operator training not given input and output material |
| Root Cause (Occurance) | input and output material separate rack not provide in machine input output material bin not different use not add point W.I |
Root Cause Analysis (Outflow)
| Why 1 | THREADING MISSING-WITHOUT THREADING |
| Why 2 | The part skipped the Final Inspection during part inspection |
| Why 3 | NG PART SKIPPED FROM INSPECTION |
| Why 4 | Final inspection area Red Bin Lock and key not available |
| Why 5 | |
| Root Cause (Outflow) | Final inspection area rejection box lock and key not available |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Input and output material separate rack provide in machine | Mr Anil | 14/08/2024 | 14/08/2024 | Completed |
| Outflow | provide All inspection table rejection bin lock and key | Mr Ganesh Maurya | 14/08/2024 | 14/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% THREADING CHECKED IN MACHINE AND FINAL INSPECTION |
| 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) |
input and output material separate rack not provide in machine input output material bin not different use not add point W.I 1017_Occurance_Before.xlsx |
| Occurance (After) |
input and output material separate rack provide in machine and input material blue and output material green bin use add point W.I 1017_Occurance_After.xlsx |
| Outflow (Before) |
Final inspection area rejection box lock and key not available 1017_Outflow_Before.xlsx |
| Outflow (After) |
Final inspection area rejection box lock and key available 1017_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | ROOLING MACHINE -01 |
12. Document Review
| Documents | PFMEA, WISOP, PackingStd |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | OK |