QFR No - 8000892843
Defect Details
| NC No. | 8000892843 |
| NC Date | 25/09/2024 |
| NC Submission Date | |
| Part No. | S3JL00731B |
| Part Name | PISTON ROD FINISH GROUND |
| Supplier Name & Code | 100993-MAYUR INDUSTRIES |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | LENGTH UNDERSIZE-T.LENGTH U/SSPE=179.00+/-0.20 OBS=176.66 |
1. Problem Description
| Defect Description | Total Length undersize obs.- 176.66 against Spec- 179.00 ± 0.20 |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 28 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qa@mayurgroup.co.in |
| Plant Head/CEO Email ID | mayurind2013@outlook.com |
| MD Email ID | rautrao@hotmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
400
|
0
|
0
|
0
|
0
|
400
|
| Check Qty |
400
|
0
|
0
|
0
|
0
|
400
|
| NG Qty |
28
|
0
|
0
|
0
|
0
|
28
|
| Scrap | 28 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| "To verify and segregate all suspected piston rod materials at both ETL`s end and our end. Problematic materials will be scrapped, and measures will be taken to prevent the same issue from recurring." |
3. Process Flow
| Process Flow Description |
|---|
| Process Flow: Piston Rod Manufacturing Incoming Material 1. Receipt of Raw Material 2. Receiving Material Inspection Material Handling 1. Raw Material Storage (RM Storage) Machining Operations 1. Bandsaw Cutting 2. CNC Machining - 1 (CNC-1) 3. CNC Machining - 2 (CNC-2) 4. Milling 5. Threading - 1 6. Threading - 2 Grinding Operations 1. Rough Grinding 2. Semi-Finish Grinding 3. Finish Grinding Quality Control 1. Final Inspection Outgoing Material 1. Packing 2. Dispatch This process flow map can help identify potential bottlenecks, optimize production, and ensure quality control. |
4. Process Details
| Process / Operation | Grinding Operation |
| Outsource | No |
| Machine / Cell | Grinding & Threading Cell |
| Machine / Cell No. | Grinding machine 4 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Occurrence | Error proofing for occurrence of material defect | X |
| Method | System | Place for stage wise process parts is fixed | X |
| Method | Unskilled Operator | operator is aware of the cause of defects | O |
| Method | Detection | System of effective In process inspection exist | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5/200 |
7. Root Cause Analysis (Occurance)
| Why 1 | Mixing problem of lesser length difference piston rods occurred because material was kept in the adjacent bins. |
| Why 2 | Processing of less length difference piston rods was planned on adjacent machines simultaneously. |
| Why 3 | Identification system of piston rods to enhanced. |
| Why 4 | Fixed place for deferent type of piston rods with respect to their process stage |
| Why 5 | Awareness of concern person to be enhanced in this regards. |
| Root Cause (Occurance) | Mixing of piston rods because of less length difference and scope of improvement in the part identification system |
Root Cause Analysis (Outflow)
| Why 1 | Length of piston rod to be inspected after finish grinding and to be added in the in process inspection report. |
| Why 2 | Sample size in the final inspection is to be enhanced. |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | System of in process inspection and final inspection is to be closely monitored. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1) Machine loading plan for identical length piston rods is done such that said piston rods are not processed on adjucent machines simultaniously. 2) Identification of piston rods ( Tagging system ) is closely monitored. 3) Stage wise area for different type of piston rod is marked and fixed. 4) Online training to the concern persons is provided and awareness in regards with consequences of the problems is done. | Mr. Ganesh Wagh | 02/10/2024 | 02/10/2024 | Completed |
| Outflow | 1) Length inspection after finish grinding is enhanced ( Inprocess inspection ). 2) Final inspection stage sample size is increaed from 10 nos to 20 nos in 200 nos. 3) OPL is displayed at the respective working places in regards with the occurred problem. | Mr. Milind Barde | 04/10/2024 | 04/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Length inspection after finish grinding is enhanced ( In process inspection ). |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10/200 |
10. Evidance of Countermeasure
| Occurance (Before) |
1) Machine loading plan for identical length piston rods is not done such that said piston rods are processed on adjacent machines simultaneously.
2) Identification of piston rods ( Tagging system ) is monitored.
3) Stage wise area for different type of piston rod is not marked. 1115_Occurance_Before.pdf |
| Occurance (After) |
1) Machine loading plan for identical length piston rods is done such that said piston rods are not processed on adjucent machines simultaniously.
2) Identification of piston rods ( Tagging system ) is closely monitored.
3) Stage wise area for different type of piston rod is marked and fixed.
4) Online training to the concern persons is provided and awareness in regards with consequences of the problems is done. 1115_Occurance_After.pdf |
| Outflow (Before) |
1) Length inspection after finish grinding is not done ( In process inspection ).
2) Final inspection stage sample size is increased from 05 no`s in 200 nos. 1115_Outflow_Before.pdf |
| Outflow (After) |
1) Length inspection after finish grinding is enhanced ( In process inspection ).
2) Final inspection stage sample size is increased from 10 no`s to 20 no`s in 200 nos.
3) OPL is displayed at the respective working places in regards with the occurred problem. 1115_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | GRINDING MACHINE |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | OPL Displayed |
13. Effectiveness Of Action
| Reviewed Quantity | 150 |
| Reason for submission | evidence of counter measure not matched as per action taken. |