QFR No - 8000894558
Defect Details
| NC No. | 8000894558 |
| NC Date | 05/10/2024 |
| NC Submission Date | |
| Part No. | F2FA28133M |
| Part Name | FORK PIPE MACHINED - Ø37.1 |
| Supplier Name & Code | 100576-SANGKAJ BRIGHT WIRES PVT LTD |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-THREADING NG |
1. Problem Description
| Defect Description | THREADING NG |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 22 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | brightwire.qa@sangkaj.com |
| Plant Head/CEO Email ID | steel@sangkaj.com |
| MD Email ID | anirudh.2007@hotmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
750
|
0
|
0
|
450
|
350
|
1550
|
| Check Qty |
750
|
0
|
0
|
450
|
350
|
1550
|
| NG Qty |
22
|
0
|
0
|
0
|
0
|
22
|
| Scrap | 22 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1) At ETL end verified the 750 nos out of 22 nos found defective.2) At SBWPL end verified the 800 nos all part found ok. 3) for ok part provided the identification mark. |
3. Process Flow
| Process Flow Description |
|---|
| Receipt Of Material - Inward Inspection - CNC 1st Setup - CNC 2nd Setup - Drilling - Final Inspection - Air Cleaning - Dispatch |
4. Process Details
| Process / Operation | CNC 2nd Setup |
| Outsource | No |
| Machine / Cell | Machining |
| Machine / Cell No. | Fork Pipe Machining |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Due to Inspector negligence. | Verified found not ok | X |
| Tool | Tool holder loose | Verified Ok | O |
| Tool | Insert Wear Out | Verified Ok | O |
| Method | Part Touch with stand, No arrangement to avoid the fork pipe contact with stand | Verified found not ok | X |
| Machine | Spindle run out not ok | Verified Ok | O |
| Man | New Operator | Verified Ok | O |
| Material | Material grade not ok | Verified Ok | O |
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 | Fork Pipe threading NG |
| Why 2 | Thread ring gauge not qualify |
| Why 3 | Dent on threading |
| Why 4 | Fork pipe directly kept on Metal stand |
| Why 5 | No arrangement to avoid the contact of stand & fork pipe. |
| Root Cause (Occurance) | No arrangement to avoid the contact of stand & fork pipe. |
Root Cause Analysis (Outflow)
| Why 1 | Fork Pipe threading NG |
| Why 2 | Skipped from inspector. |
| Why 3 | Due to Inspector negligence. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Due to Inspector negligence. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 1) Identification mark provided after final inspection for threading ok 2) Display OPL at machining & final Inspection stage. | Mr. Nitin Puri | 11/10/2024 | 11/10/2024 | Completed |
| Occurance | Blue sheet provided to avoid the threading damage issue. | Mr. Barik & Mr. Nitin Puri | 11/10/2024 | 11/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No Change |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | PDIR |
10. Evidance of Countermeasure
| Occurance (Before) |
Fork pipe kept on stand,No arrangement for avoid the threading damage 1138_Occurance_Before.xlsx |
| Occurance (After) |
Blue sheet provided to avoid the threading damage issue. 1138_Occurance_After.xlsx |
| Outflow (Before) |
Identification mark not provided after final inspection. 1138_Outflow_Before.xlsx |
| Outflow (After) |
1) Identification mark provided after final inspection for threading ok
2) Display OPL at machining & final Inspection stage. 1138_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All model |
12. Document Review
| Documents | WISOP |
| Specify Other Document | Display OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 120 |
| Reason for submission | Verified next lot observed ok |