QFR No - 8000897821
Defect Details
| NC No. | 8000897821 |
| NC Date | 29/10/2024 |
| NC Submission Date | |
| Part No. | 520PA01602 |
| Part Name | TUBE RING BOTTOM |
| Supplier Name & Code | 101255-MAHAVIR INDUSTRIES |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | ID UNDERSIZE-ID U/S SPE=29.0+/-0.10 OBS=28.40 |
1. Problem Description
| Defect Description | ID UNDERSIZE-ID U/S SPE=29.0+/-0.10 OBS=28.40 |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 49 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@mahavirind.co.in |
| Plant Head/CEO Email ID | planthead@mahavirind.co.in |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1800
|
0
|
0
|
0
|
0
|
1800
|
| Check Qty |
1800
|
0
|
0
|
0
|
0
|
1800
|
| NG Qty |
49
|
0
|
0
|
0
|
0
|
49
|
| Scrap | 49 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Material segregation at Customer End |
3. Process Flow
| Process Flow Description |
|---|
| RM inward - store - Traub Machining -1 -chamfer Machining -2- Final Inspection - Packing - Dispatch - Transport |
4. Process Details
| Process / Operation | Traub Machining |
| Outsource | Yes |
| Machine / Cell | Traub No, 5 |
| Machine / Cell No. | Traub Section |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Parting Machining Method Change , Inspection Method Change | Traub Machining Method is Correct But pipe ID not Inspection Before parting on Parting Process.. | X |
| Material | Wrong Size And other grade Material Use | Grade was ok but ID under size Pipe Mix With ok Raw Material . | X |
| Tool | Wrong Chamfer Tool Use | No, Insert Type Chamfer Tool Use on chamfer machine . | O |
| Machine | Machine Condition Not Ok | As Per PM schedule Traub Machine Found Ok | O |
| Man | Unskilled operator | As per Skilled Matrix Operator is skilled | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 20nos |
7. Root Cause Analysis (Occurance)
| Why 1 | D UNDERSIZE-ID U/S |
| Why 2 | ID Under size One Pipe mix With Ok Regular Raw Material. |
| Why 3 | Operator Not aware for ID under size. In Regular Operation. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | ID Under size One Pipe mix With Ok Regular Raw Material. |
Root Cause Analysis (Outflow)
| Why 1 | D UNDERSIZE-ID U/S |
| Why 2 | ID Under size One Pipe mix With Ok Regular Raw Material. |
| Why 3 | The operator on the Traub machine did not check the first parting piece after loading a new pipe. |
| Why 4 | Operator Not aware for ID under size. In Regular Operation. |
| Why 5 | |
| Root Cause (Outflow) | The operator on the Traub machine did not check the first parting piece after loading a new pipe. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Work Instructions Display on Traub Machine for Operator Awareness | Production Incharge | 08/11/2024 | 07/11/2024 | Completed |
| Outflow | Plug Gauge Provide On Traub Machine for check the first parting piece after loading a new pipe. | Quality Head | 17/11/2024 | 16/11/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Plug Gauge Provide On Traub Machine for check the first parting piece after loading each and Every a New Pipe |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 20Pcs |
10. Evidance of Countermeasure
| Occurance (Before) |
ID Under size One Pipe mix With Ok Regular Raw Material. 1196_Occurance_Before.docx |
| Occurance (After) |
Work Instructions Display on Traub Machine for Operator Awareness. 1196_Occurance_After.docx |
| Outflow (Before) |
The operator on the Traub machine did not check the first parting piece after loading a new pipe. 1196_Outflow_Before.docx |
| Outflow (After) |
lug Gauge Provide On Traub Machine for check the first parting piece after loading a new pipe. 1196_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Tube Rings |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |