QFR No - 8000896112
Defect Details
| NC No. | 8000896112 |
| NC Date | 17/10/2024 |
| NC Submission Date | |
| Part No. | F2KH01002B |
| Part Name | REBOUND SPRING-XF121 |
| Supplier Name & Code | 101159-TECHNOMAT SPRINGS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | BEND-BEND |
1. Problem Description
| Defect Description | Bend |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 6 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@technomatsprings.com |
| Plant Head/CEO Email ID | technomatsprings@gmail.com |
| MD Email ID | patilsadanand@technomatsprings.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
15000
|
0
|
0
|
28000
|
0
|
43000
|
| Check Qty |
15000
|
0
|
0
|
28000
|
0
|
43000
|
| NG Qty |
6
|
0
|
0
|
0
|
0
|
6
|
| Scrap | 6 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Checked all material at customer end and pipeline material also. |
3. Process Flow
| Process Flow Description |
|---|
| R/m In-warding Inspection > Coiling > Stress Relieving-1 > Grinding > Shot Peening > Stress Relieving-2 > Final Inspection > Oiling > Packing > Dispatch. |
4. Process Details
| Process / Operation | coiling |
| Outsource | No |
| Machine / Cell | - |
| Machine / Cell No. | - |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Wrong Material / Grade | Supplier RMTC Report checked found Ok | O |
| Man | Unskilled Operator | Skilled matrix found ok | O |
| Tool | Tool Loose / Tool thread wear out | found pitch tool locking bolt thread wear out | X |
| Machine | Machine check Sheet not followed | Found machine JH activity done as per the mentioned freq. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 50 Nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Un-Grounded Spring observed. |
| Why 2 | Grinding operation not done. |
| Why 3 | spring length undersized in coiling operation. |
| Why 4 | Due to pitch tool locking thread wear out. |
| Why 5 | No check point available for thread locking wear out in JH check sheet. |
| Root Cause (Occurance) | No check point available for thread locking wear out in JH check sheet. |
Root Cause Analysis (Outflow)
| Why 1 | Un-Grounded Spring observed. |
| Why 2 | Defective parts escaped from inspection. |
| Why 3 | Defective parts was few due to that not arrested in insp. |
| Why 4 | Inspection Done on sampling Basis. |
| Why 5 | |
| Root Cause (Outflow) | Inspection done on sampling basis and defective parts were less so not arrested in final inspection. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 100% Visual Inspection started. | Mr. Anuj Shelke | 07/11/2024 | 07/11/2024 | Inprocess |
| Occurance | Check point added in JH check sheet. | Mr. Khandare | 07/11/2024 | 07/11/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% visual inspection started. |
| 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) |
In the JH check sheet,the nut bolt looseness point was not mentioned. 1167_Occurance_Before.xlsb |
| Occurance (After) |
In the JH check sheet, nut bolt looseness point has been added. 1167_Occurance_After.xlsb |
| Outflow (Before) |
Inspection done as per the sampling plan. 1167_Outflow_Before.xlsb |
| Outflow (After) |
100% inspection has started. 1167_Outflow_After.xlsb |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Horizontally deployed for the all similar machines. |
12. Document Review
| Documents | JHCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |