QFR No - 8000895378
Defect Details
| NC No. | 8000895378 |
| NC Date | 13/10/2024 |
| NC Submission Date | |
| Part No. | 530MJ00102 |
| Part Name | SPRING SEAT |
| Supplier Name & Code | 100144-AURANGABAD PRESSINGS |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | DIAMETER OVER SIZE-O/D OVER SIZE SPE=81.0+/-0.50 OBS=83.90 |
1. Problem Description
| Defect Description | DIAMETER OVER SIZE-O/D OVER SIZE SPE=81.0+/-0.50 OBS=83.90 |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 5 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@apw3.co.in |
| Plant Head/CEO Email ID | aurangabadpressings@apw3.co.in |
| MD Email ID | shashikant@apw3.co.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
3000
|
0
|
0
|
0
|
10000
|
13000
|
| Check Qty |
3000
|
0
|
0
|
0
|
0
|
3000
|
| NG Qty |
5
|
0
|
0
|
0
|
0
|
5
|
| Scrap | 5 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Material segregation at ETL end |
3. Process Flow
| Process Flow Description |
|---|
| Blanking /Is forming /piercing/Draw /2nd draw /Trimming |
4. Process Details
| Process / Operation | Trimming |
| Outsource | No |
| Machine / Cell | Press Machine |
| Machine / Cell No. | Press shop |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Without Trimming | Without Trimming passed | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 pic |
7. Root Cause Analysis (Occurance)
| Why 1 | OD Over size 81.0 +/-0.5 Over size 83.9 |
| Why 2 | OD Over size 81.0 +/-0.5 Over size 83.9 |
| Why 3 | Trimming part size 80.3 & before trimming 83.8 |
| Why 4 | Can not inspect by visual inspection |
| Why 5 | |
| Root Cause (Occurance) | So Without Trimming component MIX up with ok component |
Root Cause Analysis (Outflow)
| Why 1 | OD Over size 81.0 +/-0.5 Over size 83.9 |
| Why 2 | OD Over size 81.0 +/-0.5 Over size 83.9 |
| Why 3 | Trimming part size 80.3 & before trimming 83.8 |
| Why 4 | Can not inspect by visual inspection |
| Why 5 | |
| Root Cause (Outflow) | So Without Trimming component MIX up with ok component |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Mixup without trimming | Deepak | 13/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Before -Sampling Inspection .After -100% Inspection by Gauge |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Inspection Method Change 1146_Occurance_Before.pdf |
| Occurance (After) |
Inspection Method Change 1146_Occurance_After.pdf |
| Outflow (Before) |
Inspection Method Change 1146_Outflow_Before.pptx |
| Outflow (After) |
Inspection Method Change 1146_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Press machine / Inspection Gauge |
12. Document Review
| Documents | ControlPlan, InspCheckSheet |
| Specify Other Document | PFD |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | diameter found with in specification. |