QFR No - 8000894559
Defect Details
| NC No. | 8000894559 |
| NC Date | 05/10/2024 |
| NC Submission Date | |
| Part No. | 550FA12233 |
| Part Name | FORK PIPE MACHINED - K3 |
| Supplier Name & Code | 100576-SANGKAJ BRIGHT WIRES PVT LTD |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-SHORT LENGTH |
1. Problem Description
| Defect Description | SHORT LENGTH |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 27 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | brightwire.qa@sangakj.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
|
1200
|
650
|
2600
|
| Check Qty |
750
|
0
|
0
|
0
|
0
|
750
|
| NG Qty |
27
|
0
|
0
|
0
|
0
|
27
|
| Scrap | 27 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1) At ETL end verified 750 nos out of 27 nos found defective 2) At SBWPL end verified 1850 nos foun ok. 3) Provided identification mark on ok part. |
3. Process Flow
| Process Flow Description |
|---|
| Receipt of Material - inward inspection - CNC 1st Setup - CNC 2nd Setup - Ø5 Drilling - Final Inspection - Air Cleaning - Dispatch |
4. Process Details
| Process / Operation | CNC 2nd Setup |
| Outsource | No |
| Machine / Cell | CNC Cell |
| Machine / Cell No. | Fork Pipe Cell |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | New Operator | Verified Ok | O |
| Machine | Wrong offset | Verified ok | O |
| Material | Wrong material Received | Verified Ok | O |
| Man | Inspector/ operator negligence-during Inspection/ process | Verified found not ok | X |
| Method | No arrangement to remove the stopper stick burr | Verified found not ok | X |
| Tool | Insert Wear Out | Verified found ok | O |
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 | Fork pipe short length |
| Why 2 | Fork pipe not properly rest on stopper face |
| Why 3 | Machining loose burr stack on stopper face |
| Why 4 | No arrangement to remove the stopper stack burr. |
| Why 5 | |
| Root Cause (Occurance) | No arrangement to remove the stopper stack burr. |
Root Cause Analysis (Outflow)
| Why 1 | Fork pipe short length |
| Why 2 | Skipped from operator & inspector. |
| Why 3 | Due to operator & inspector negligence. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Due to operator & inspector negligence. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Air flushing provided on CNC machining to remove the stack burr. | Mr. Barik & Mr. Nitin Puri | 11/10/2024 | 11/10/2024 | Completed |
| Outflow | 1) 100% inspection with the help of Spl gauge at machining stage 100% & final inspection doing 15 days. | 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 in inspection method |
| Inspection Method | Sp. Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
No arrangement of air flushing to remove the stuck burr. 1135_Occurance_Before.xlsx |
| Occurance (After) |
Provided Air flushining rrangement to remove the stuck burr. 1135_Occurance_After.xlsx |
| Outflow (Before) |
Identification mark not provided after final inspection. 1135_Outflow_Before.xlsx |
| Outflow (After) |
1) Identification mark provided after final inspection.
2) 100% inspection with the help of spl. height gauge.
3) Sampling Basis inspection with the help of DHG 1135_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applicable all model & machine |
12. Document Review
| Documents | WISOP |
| Specify Other Document | Display OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 58 |
| Reason for submission | Verified lot found Ok |