QFR No - 8000889012
Defect Details
| NC No. | 8000889012 |
| NC Date | 29/08/2024 |
| NC Submission Date | |
| Part No. | S2KH01402B |
| Part Name | REBOUND SPRING U101 |
| Supplier Name & Code | 101159-TECHNOMAT SPRINGS |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | M/CING SHIFT.-NOTCH BURR |
1. Problem Description
| Defect Description | INSIDE ID NOTCH BURR |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 439 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@technomatsprings.com |
| Plant Head/CEO Email ID | technomatsprings@gmail.com |
| MD Email ID | patilsadanand@technomatsprings.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
6000
|
0
|
0
|
840
|
0
|
6840
|
| Check Qty |
6000
|
0
|
0
|
840
|
0
|
6840
|
| NG Qty |
439
|
0
|
0
|
0
|
0
|
439
|
| Scrap | 0 |
| Rework | 439 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material checked 100% for nose burr issue at ETL end and Technomat end also. |
3. Process Flow
| Process Flow Description |
|---|
| RM In warding > RM Inspection > Coiling > Stress Relieving-1 > Grinding > De-Burring > Shot Peening > Stress Relieving-2 > Final Inspection > Oiling > Packing > Dispatch. |
4. Process Details
| Process / Operation | Coiling |
| Outsource | No |
| Machine / Cell | - |
| Machine / Cell No. | - |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | NA | NA | O |
| Material | Wrong Material / Grade | Supplier RMTC Report checked found Ok | O |
| Man | Unskilled Operator | Skill Matrix verified found Ok | O |
| Tool | Tool Wear Out | Tool Monitoring Card Verified found ok | O |
| Method | Nose Burr Operation Skipped. | Process re-verified & observed that the nose burr operation skipped. | 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 | 30 Nos |
7. Root Cause Analysis (Occurance)
| Why 1 | NOSE BURR OBSERVED. |
| Why 2 | INSPECTION SKIPPED AT THE TIME OF SET-UP APPROVAL. |
| Why 3 | DUE TO NOSE BURR OPERATION NOT MENTIONED ON THE SET-UP REPORT. |
| Why 4 | OPERATOR NOT AWARE ABOUT THE NOSE BURR OPERATION. |
| Why 5 | |
| Root Cause (Occurance) | THE NOSE BURR OPERATION NOT MENTIONED ON THE SETUP REPORT DUE TO THAT OPERATOR NOT AWARE ABOUT NOSE BURR OPERATION. |
Root Cause Analysis (Outflow)
| Why 1 | NOSE BURR OBSERVED. |
| Why 2 | DEFECTIVE PART SKIPPED FROM INSPECTION |
| Why 3 | PARTS NOT CHECKED FOR THE NOSE BURR DEFECT AT FINAL INSPECTION. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | PARTS NOT CHECKED FOR THE NOSE BURR DEFECT AT FINAL INSPECTION. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1. NOSE BURR OPERATION POINT ADDED IN SET UP REPORT 2. PART-WISE LIST FOR THE NOSE BURR PROCESS DISPLAYED ON THE MACHINE. | MR. ANUJ SHELKE | 25/09/2024 | 25/09/2024 | Completed |
| Outflow | 1. TRAINING GIVEN TO THE INSPECTORS 2. OPL DISPLAYED AT FINAL INSPECTION STAGE. | MR. ANUJ SHELKE | 25/09/2024 | 25/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 1. NOSE BURR OPERATION LIST DISPLAYED ON THE MACHINE. 2. TRAINING GIVEN TO THE OPERATORS AND INSPECTORS AND OPERATORS |
| 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) |
De-burring point was not mentioned on the control plan. 1049_Occurance_Before.pdf |
| Occurance (After) |
De-burring point mentioned on the control plan. 1049_Occurance_After.pdf |
| Outflow (Before) |
Material Checked on the sampling basis. 1049_Outflow_Before.pdf |
| Outflow (After) |
100% inspection started. & OPL Displayed at the final inspection table. 1049_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Horizontally deployed for all the same parts. |
12. Document Review
| Documents | ControlPlan, WISOP |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | After taking action no notch burr observed on part. |