QFR No - 8000895939
Defect Details
| NC No. | 8000895939 |
| NC Date | 17/10/2024 |
| NC Submission Date | |
| Part No. | F2DZ04603B |
| Part Name | FORK BOLT J1A & J1D |
| Supplier Name & Code | 100189-SANGKAJ STEEL PVT LTD. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-GROOVE WITH UNDER SIZE |
1. Problem Description
| Defect Description | Groove width undersize Specification: 4.5 +0.2 Observation: 2.88 |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualityassurance@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 |
288
|
0
|
0
|
550
|
300
|
1138
|
| Check Qty |
288
|
0
|
0
|
550
|
300
|
1138
|
| NG Qty |
0
|
0
|
0
|
0
|
0
|
0
|
| Scrap | 0 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All the Material at Endurance & at sangkaj steel checked and no NG part Found |
3. Process Flow
| Process Flow Description |
|---|
| RM Inward and inward Inspection-Wire Drawing-Straightening-Bar Parting-CNC 1st- CNC2nd-Milling-Tapping-plating-Final Inspection-Packing & Dispatch |
4. Process Details
| Process / Operation | CNC turning 2nd |
| Outsource | Yes |
| Machine / Cell | CNC Machine |
| Machine / Cell No. | 2 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Insert Broken | Defective piece observed with groove width undersize by1.62mm, which occures only after insert break | X |
| Man | New operator | Regular and Experienced operator Dployed for Production. | O |
| Material | Input Material Not OK | Cut Blanks found ok as all the blanks are cut through same bar. | O |
| Machine | Variation due to machine | Variation due to Machine not Causes dimension undersize by 1.62mm | O |
| Method | Less Sampling Size | Groove width is checked with width gauge on Sampling basis. | 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 | 10:100 |
7. Root Cause Analysis (Occurance)
| Why 1 | Groove Width Undersize Part Found at Customer End |
| Why 2 | Incomplete Operation is done during Grooving. |
| Why 3 | Insert Broken before the Set Tool Life. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Insert Broken before the Set Tool Life. |
Root Cause Analysis (Outflow)
| Why 1 | Groove Width Undersize Part Found at Customer End |
| Why 2 | Defective Parts Skipped from the Final Inspection |
| Why 3 | Part Checked on Sampling basis with slip type width gauge. |
| Why 4 | Less Sampling Size |
| Why 5 | |
| Root Cause (Outflow) | Less Sampling Size during Final Inspection. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Revalidation of Insert Life is done by varying the Process Parameters. Previous set Life was 800 No`s Per Side. By Setting the Process Parameters at extreme limit of their Specification, the new Insert Life set is 700 No`s. | Mr. Santosh Raut | 22/10/2024 | 22/10/2024 | Completed |
| Outflow | Inspection method Changed. 100% Inspection of Groove with Slip type Width Gauge is done During the Final Inspection. | Mr. A.A. Joshi | 22/10/2024 | 22/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection of Groove with Slip type WIdth Gauge. |
| 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) |
Tool Life-800 Nos 1157_Occurance_Before.pptx |
| Occurance (After) |
Tool Life -700 Nos 1157_Occurance_After.pptx |
| Outflow (Before) |
Inspection on Sampling Basis 1157_Outflow_Before.pptx |
| Outflow (After) |
100% Inspection with Width gauge 1157_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Fork Bolt AABM |
12. Document Review
| Documents | ControlPlan, InspCheckSheet |
| Specify Other Document | No Other |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | Interlocking required for tool breakage |