QFR No - 8000895030
Defect Details
| NC No. | 8000895030 |
| NC Date | 08/10/2024 |
| NC Submission Date | |
| Part No. | F800506807 |
| Part Name | UNDER BRACKET ASSY-5TSF |
| Supplier Name & Code | 100576-SANGKAJ BRIGHT WIRES PVT LTD |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-STEERING SHAFT & M6 THREAD RUSTY |
1. Problem Description
| Defect Description | Under bracket rusty |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 223 |
| 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 |
600
|
0
|
0
|
450
|
225
|
1275
|
| Check Qty |
600
|
0
|
0
|
450
|
225
|
1275
|
| NG Qty |
223
|
0
|
0
|
0
|
0
|
223
|
| Scrap | 223 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1) At ETL end verified 600 Nos out of 223 nos found defective. 2) At SBWPL end verify 675 nos parts & all parts found ok. 3) For ok parts provided 100 % Verification identification marking on Top face of M6 Tapping. |
3. Process Flow
| Process Flow Description |
|---|
| Material Receipt - Inward inspection - Rough boring - Boss Drilling LH & RH - Ø5 Drilling - Boss Facing - Ø5 Drilling - Top Boss Tapping - Frant Boss Tapping - Bracket Slitting - Counter Drilling - Bracket Chamfering - Bracket Debarring - Shaft & bracket pressing - Shaft & bracket welding - Wire brushing - Powder coating inward - Fine boring - M6X1-6H Re-tapping - M8X1.25-6H Tapping - Final Inspection - Rust Oil Application - Packaging & Dispatch. |
4. Process Details
| Process / Operation | Tapping |
| Outsource | No |
| Machine / Cell | Tapping |
| Machine / Cell No. | Tapping Cell |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | There was no any further provision for applying RPO inside M6 threading. | Verified Not Ok | X |
| Machine | Use rusty M6 Tap | Verified Ok | O |
| Material | RPO Oil use non standard | Verified Ok | O |
| Method | Packaging damage | Verified Ok | O |
| Man | Inspector / Operator New | Verified Ok | O |
| Man | Inspector/ operator negligence-during Inspection/ process | Verified Not Ok | X |
| Machine | Tapping Oil use non standard | Verified Ok | O |
| Material | Inward Material Rusty | Verified Ok | O |
| Method | Inventory excess | Verified ok | O |
| Material | RPO Not available | Verified Ok | O |
| Method | FIFO Not maintained | Verified ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | M6X1-6H Threading Rusty |
| Why 2 | Lack of RPO inside M6X1-6H threading. |
| Why 3 | RPO applied only during tapping operation. |
| Why 4 | There was no any further provision for applying RPO inside M6 threading. |
| Why 5 | |
| Root Cause (Occurance) | There was no any further provision for applying RPO inside M6 threading. |
Root Cause Analysis (Outflow)
| Why 1 | M6X1-6H Threading Rusty |
| 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 |
|---|---|---|---|---|---|
| Occurance | 1.100 % RPO is to be applying inside M6 threading with the help of spl oil bottle. 2) Provided separate bin with RPO for dipping the part after final inspection. 3. Updated in the control plan & PFMEA for M6X1-6H threading Rusty. | Mr. Mukesh Rathod Mr. Manoj Pathe | 11/10/2024 | 11/10/2024 | Completed |
| Outflow | 1) For ok parts provide 100 % Verification identification marking on Top face of M6 Tapping. 2) OPL displayed at tapping & final inspection stages for visual inspection. | Mr. Mukesh Rathod Mr. Manoj Pathe | 10/10/2024 | 11/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No change in inspection method after customer complaint |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
RPO was applying during tapping only. 1139_Occurance_Before.xlsx |
| Occurance (After) |
1.100 % RPO is to be applying inside M6 threading with the help of spl oil bottle. 2) Provided separate bin with RPO for dipping the part after final inspection.
3. Updated in the control plan & PFMEA for M6X1-6H threading Rusty. 1139_Occurance_After.xlsx |
| Outflow (Before) |
Identification not provided after final inspection for M6 threading rusty. 1139_Outflow_Before.xlsx |
| Outflow (After) |
1.Provide On job Training and awareness given to all inspectors and Tapping Operator for M6X1-6gH Threading rusty & its Importance
2.Display the OPL for M6X1-6H Threading Rusty at Final inspection stage.
3.For ok parts provide 100 % Verification identification marking. 1139_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All models |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | OPL Display |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | OK |