QFR No - 8000889503
Defect Details
| NC No. | 8000889503 |
| NC Date | 02/09/2024 |
| NC Submission Date | |
| Part No. | F2GN11802B |
| Part Name | MAIN SPRING-ABWB ENDURO |
| Supplier Name & Code | 100952-STUMPP SCHUELE AND SOMAPPA SPR |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | LENGTH OVERSIZE-TOTAL LENGTH OVERSIZE |
1. Problem Description
| Defect Description | TOTAL LENGTH OVERSIZE |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 129 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | hravikumar@ssssprings.com |
| Plant Head/CEO Email ID | sreenivasulu.k@ssssprings.com |
| MD Email ID | rln@ssssprings.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1500
|
0
|
0
|
300
|
0
|
1800
|
| Check Qty |
1500
|
0
|
0
|
300
|
0
|
1800
|
| NG Qty |
129
|
0
|
0
|
0
|
0
|
129
|
| Scrap | 129 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| After Receipt of Complaint 100% Parts Verify at ETL End as Well as Inhouse for Length Undersize Issue, At ETL found 129 no`s Length Undersize spring |
3. Process Flow
| Process Flow Description |
|---|
| Coiling - Tempering-Grinding-Shot Peening - Setting-100% Lo Inspection-2nd Tempering-Visual Inspection-Oiling-Final Inspection-FG Storage-Packing-Dispatch |
4. Process Details
| Process / Operation | Setting / Lo Inspection |
| Outsource | No |
| Machine / Cell | FF Cell |
| Machine / Cell No. | 02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Operator Verified only Part Name not Item Code | Operator not verified Properly Item Code | X |
| Method | At Setting (Scragging) & Length Inspection Stage Improper Set-up | Operator Set-up at Scragging Stage length as per Similar name ABWB ADJUSTABLE. instead of ABWB | X |
| Method | 100% Length Operator Set Universal Snap Gauge as Per ABWB ADJS. (E92 Parts) and Checked Length | Due to Same Name- As per ABWB ADJS. Length inspection carried (ABWB ADJS. Length is less than ABWB ) | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Length Undersize Spring Observed |
| Why 2 | At Setting (Scragging) Stage Improper Set-up |
| Why 3 | Due to Similar name ABWB ADJUSTABLE. instead of ABWB Operator Set-up at Scragging Stage length as per ABWB Adjustable |
| Why 4 | Operator less aware about Similar Model-As per Tag Name Mentioned only ABWB |
| Why 5 | Due to this Length Undersize issue Happen |
| Root Cause (Occurance) | Due to Similar name ABWB & ABWB Adjs. Operator Set-up Scragging as per ABWB Adjs. |
Root Cause Analysis (Outflow)
| Why 1 | Length Undersize Spring Observed |
| Why 2 | 100% Length Operator Set Universal Snap Gauge as Per ABWB ADJS. (E92 Parts) and Checked Length |
| Why 3 | Due to this Length Undersize issue observed |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | 100% Length Operator Set Universal Snap Gauge as Per ABWB ADJS. (E92 Parts) and Checked Length- Due to Similar name |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Similar Parts Lengthwise Matrix Made and Displayed on Scragging Stage - (As well Inform to Operator to verify as per Item Code ) | Mr. Ishwar Jadhav | 05/09/2024 | 01/09/2024 | Completed |
| Occurance | Earlier Universal Gauge Set -up with Vernier Caliper, Now We have Made Spring wise Limit Sample for Length Set-up, Operator Can Compare with Respective Model | Mr. Shankar Fadat | 06/09/2024 | 06/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | Earlier Universal Gauge Set -up with Vernier Caliper, Now We have Made Spring wise Limit Sample for Length Set-up, Operator Can Compare with Respective Model During Scragging Set-up |
| 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) |
Due to Similar name ABWB & ABWB Adjs. Operator Set-up Scragging as per ABWB Adjs. 1060_Occurance_Before.pdf |
| Occurance (After) |
Similar Parts Lengthwise Matrix Made and Displayed on Scragging Stage - (As well Inform to Operator to verify as per Item Code ) 1060_Occurance_After.pdf |
| Outflow (Before) |
100% Length Operator Set Universal Snap Gauge as Per ABWB ADJS. (E92 Parts) and Checked Length- Due to Similar name 1060_Outflow_Before.pdf |
| Outflow (After) |
Earlier Universal Gauge Set -up with Vernier Caliper, Now We have Made Spring wise Limit Sample for Length Set-up, Operator Can Compare with Respective Model 1060_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | FF Cell |
12. Document Review
| Documents | WISOP |
| Specify Other Document | Limit Sample |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |