QFR No - 8000890800
Defect Details
| NC No. | 8000890800 |
| NC Date | 12/09/2024 |
| NC Submission Date | |
| Part No. | F2FA19033M |
| Part Name | K0PG FORK PIPE MACHINED |
| Supplier Name & Code | 101109-TUBE INVESTMENTS OF INDIA LIMI |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | CRACK-HEAVY CRACK PART |
1. Problem Description
| Defect Description | Fork pipe K0PG crack problem. |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | anandms@tii.murugappa.com |
| Plant Head/CEO Email ID | girisha@tii.murugappa.com |
| MD Email ID | mukeshahuja@tii.murugappa.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5000
|
0
|
0
|
1500
|
67000
|
73500
|
| Check Qty |
5000
|
0
|
0
|
1500
|
12000
|
18500
|
| NG Qty |
4
|
0
|
0
|
0
|
0
|
4
|
| Scrap | 4 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % Visual inspection done for all available material at ETL after Grinding & will continue for next 1 week. & 100% Visual Inspection stated after machining operation for all available Raw material stock before dispatch to ETL. |
3. Process Flow
| Process Flow Description |
|---|
| TUBE FORMING - ANNEALING - WET PROCESS - PUSH POINTING - DRAWING - STRESS RELIEVING - STRAIGHTENING - ECT - CTL - FACING & CHAMFERING - FINAL INSPECTION - PACKING - DISPATCH TO SANAND W/H - INWARD - CNC MACHINING - DRILLING - DIBURRING - FINAL INSPECTION - PACKING - DISPATCH TO ETL. |
4. Process Details
| Process / Operation | Tube FORMING |
| Outsource | No |
| Machine / Cell | --- |
| Machine / Cell No. | --- |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Impeder damage | Auto mode paper filter mechanism monitoring every day through IMI Check list. | O |
| Method | Insufficient Argon gas flow | Inter lock available for detection alarm if in case of variation in argon flow. | O |
| Method | Fin blade broken | As Per report found Seam guide fin blades are broken while thickness change over. | X |
| Machine | Less power during start of mill | Auto paint spray unit mechnaism ( 1st Part - NG Paint spray) monitoring through IMI Check | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Eddy Current Testing |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Tube Crack found at customer end after grinding operation. |
| Why 2 | Paste weld at localized area . |
| Why 3 | 18th pass fin blade broken as Excess load act on blade side face |
| Why 4 | Small weld bead material hit on the fin blade while wall thickness change over. |
| Why 5 | Insufficient grinding of end weld joint edges with the current practice. |
| Root Cause (Occurance) | Insufficient grinding of end weld joint edges with the current practice. |
Root Cause Analysis (Outflow)
| Why 1 | Tube Crack found at customer end after grinding operation. |
| Why 2 | Crack occurred after grinding process load |
| Why 3 | Paste weld at localized area & it is not detected. |
| Why 4 | Eddy current testing m/c is not capture the defect. |
| Why 5 | |
| Root Cause (Outflow) | Eddy current testing m/c is not capture the defect. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Concave c-shape grinding to be done on both edge up to 2 mm from strip width(Grinding strip width allowance: 130 mm to 132 mm). | Mr. Satish | 15/10/2024 | 10/10/2024 | Completed |
| Occurance | The end weld ground strip to be verified snap gauge for each end weld period. | Mr. Satish | 15/10/2024 | 10/10/2024 | Completed |
| Outflow | ECT setting threshold limit changed from 50% to 40% for stringent control | Mr. Satish | 15/10/2024 | 10/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | ECT setting threshold limit changed from 50% to 40% for stringent control |
| Inspection Method | Other |
| Other Inspection Method | Eddy current testing |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
1.Fine edge bead projection even after flat grinding of end weld joint.
2. Visual inspection after every end weld grinding 1089_Occurance_Before.pptx |
| Occurance (After) |
1.Concave c-shape grinding to be done on both edge up to 2 mm from strip width.
2.The end weld ground strip to be verified snap gauge for each end weld period. 1089_Occurance_After.pptx |
| Outflow (Before) |
Eddy current test threshold setting of upper & lower controlled with 50% 1089_Outflow_Before.pptx |
| Outflow (After) |
ECT setting threshold limit changed from 50% to 40% for stringent control 1089_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | ALL TFF SIZES. |
12. Document Review
| Documents | WISOP |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |