QFR No - 8000893358
Defect Details
| NC No. | 8000893358 |
| NC Date | 27/09/2024 |
| NC Submission Date | |
| Part No. | S2MX00812B |
| Part Name | STEEL BUSH J1A & J1D |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | LENGTH OVERSIZE-T.LENGTH O/S SPE=25.20-0.20 OBS=25.26 |
1. Problem Description
| Defect Description | LENGTH OVERSIZE-T.LENGTH O/S SPE=25.20-0.20 OBS=25.26 |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 17 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@mahavirind.co.in |
| Plant Head/CEO Email ID | planthead@mahavirind.co.in |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
7000
|
0
|
0
|
0
|
6000
|
13000
|
| Check Qty |
7000
|
0
|
0
|
0
|
3000
|
10000
|
| NG Qty |
24
|
0
|
0
|
0
|
0
|
24
|
| Scrap | 0 |
| Rework | 24 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Material segregation at Customer End |
3. Process Flow
| Process Flow Description |
|---|
| RM inward - store - Traub Parting -Chamfering - Plating-Final inspection - Packing - Dispatch - Transport |
4. Process Details
| Process / Operation | Traub Parting |
| Outsource | Yes |
| Machine / Cell | Traub No.1( A-25) |
| Machine / Cell No. | Traub Section |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Machine Condition Not OK | As per Daily Check sheet Machine Condition was OK | O |
| Tool | Wrong Tool Insert Use | Correct carbide parting Tool Use But Tool Holding Issue | X |
| Man | Unskilled operator | As per Skilled Matrix Operator is skilled | O |
| Material | Wrong Grade And other grade Material Use | Correct Grade CEW-1 Material use . | O |
| Method | Machining Process & Inspection Method Wrong | Machining Process is ok But Inspection Method Wrong | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Sp. 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 oversize / under size |
| Why 2 | During the parting process, the parting tool Insrert is lightly loose on the Traub machine. |
| Why 3 | The tool Insert is not properly tightened because the bolt head is worn due to improper tightening with a spanner |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | During the parting process, the parting tool Insert is lightly loose on the Traub machine. |
Root Cause Analysis (Outflow)
| Why 1 | Length oversize / under size |
| Why 2 | Sample Basis Inspection On final Inspection stage . |
| Why 3 | No stage Wise Length gauges Only One Gauge For Both Stage |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No stage Wise Length gauges Only One Gauge For Both Stage |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | New Parting Tool Holder Replace on Traub Machine and Insert change Work Instruction Display | Production Head | 28/09/2024 | 26/09/2024 | Completed |
| Outflow | Additional New Length gauge Arrange On Final Inspection Stage for 100% Inspection. | Quality Head | 03/10/2024 | 03/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Length Inspection on final Stage Instead of 50% Inspection |
| 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) |
During the parting process, the parting tool Insert is lightly loose on the Traub machine 1118_Occurance_Before.jpg |
| Occurance (After) |
New Parting Tool Holder Replace on Traub Machine and Insert change Work Instruction Display 1118_Occurance_After.jpg |
| Outflow (Before) |
No stage Wise Length gauges Only One Gauge For Both Stage . 1118_Outflow_Before.jpg |
| Outflow (After) |
Additional New Length gauge Arrange On Final Inspection Stage for 100% Inspection. 1118_Outflow_After.docx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Steel Bush Models |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 150 |
| Reason for submission | after taking action no any issue observed. |