QFR No - 8000886629
Defect Details
| NC No. | 8000886629 |
| NC Date | 12/08/2024 |
| NC Submission Date | |
| Part No. | F2DZ04603B |
| Part Name | FORK BOLT J1A & J1D |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-FORGING DENT |
1. Problem Description
| Defect Description | FORGING DENT |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 1 |
| 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 |
400
|
0
|
0
|
300
|
0
|
700
|
| Check Qty |
400
|
0
|
0
|
300
|
0
|
700
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregated all pipeline material at ETL end and Sharp end |
3. Process Flow
| Process Flow Description |
|---|
| RM incoming-Parting and drilling-Milling-CNC 1st-Deburring-CNC 2nd-Finish Drilling--Tapping-Plating-Final Inspection-PDIR-Packing and forwarding |
4. Process Details
| Process / Operation | RM incoming |
| Outsource | Yes |
| Machine / Cell | NA |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Part not clamp properly | Clamping done properly | O |
| Tool | Tool make grade change | Tool found as per specification | O |
| Material | Hardness variation | Found ok | O |
| Material | Material in damage condition | One bar found in damage condition in same lot | X |
| Man | Unskill manpower | Skill manpower deployed | O |
| Material | Material Grade change | Grade found ok | O |
| Method | SOP not followed | SOP available on stage | O |
| Method | Fixture Not clean Properly | Fixture found clean | O |
| Man | Manpower change | Manpower deployed ase per skill matrix | O |
| Tool | Tool not change at defined frequency | Change at defined frequency | O |
| Man | Inspector Change | Inspector change coz regular inspector in on leave for one day | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 nos per |
7. Root Cause Analysis (Occurance)
| Why 1 | Deep Line mark |
| Why 2 | Deep line mark on collar |
| Why 3 | Deep line mark on RM |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Deep line mark on RM |
Root Cause Analysis (Outflow)
| Why 1 | Deep Line mark |
| Why 2 | skip from inspection |
| Why 3 | Inspector changed |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspector changed |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | started 100% inspection at supplier end with white colour identification mark and same verification at Incoming Stage | Yogesh Chavan | 22/08/2024 | 22/08/2024 | Completed |
| Outflow | on job training given to inspector also, started inspector initials tag along with bins | Omkar Bhange | 20/08/2024 | 20/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | RM verification started at incoming stage. |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
5 nos bar per lot 1021_Occurance_Before.jpeg |
| Occurance (After) |
100% checking started with white colour identification before dispatch at supplier end also verification at incoming stage. 1021_Occurance_After.jpeg |
| Outflow (Before) |
100% inspection but without inspectors tag 1021_Outflow_Before.jpeg |
| Outflow (After) |
on job training given to inspector also, started inspector initials tag along with bins 1021_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 | 50 |
| Reason for submission | Occurrence side route cause can do better and action only inspection is not sufficient need preventive action to avoid re-occurrence. Outflow side inspector change is related to 4M which is not addressed in 4M analysis and also not declared about 4M change |