QFR No - 8000903666
Defect Details
| NC No. | 8000903666 |
| NC Date | 14/12/2024 |
| NC Submission Date | |
| Part No. | F2FA30233B |
| Part Name | FORK PIPE MACHINED |
| Supplier Name & Code | 101223-SANGKAJ BRIGHT WIRES PRIVATE L |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | MATERIAL DEFECT-FORK PIPE CRACK |
1. Problem Description
| Defect Description | K1KG front fork leakage observed in fork pipe area because of fork pipe material issue(crack) |
| Detection Stage | Inprocess |
| Problem Severity | Safety |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | vqoek5tfr3bscmjep4y15qyt.gif |
Supplier Communication Details
| Quality Head Email ID | kolarbright@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 |
3920
|
0
|
0
|
2000
|
3000
|
8920
|
| Check Qty |
3739
|
0
|
0
|
2000
|
3000
|
8739
|
| NG Qty |
181
|
0
|
0
|
0
|
0
|
181
|
| Scrap | 181 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material segregated from TI Supplier(ETL+Sangkaj) |
3. Process Flow
| Process Flow Description |
|---|
| Tube Forming+ Annealing+ Wet Process + Push Pointing + Drawing + Stress releving + Straightening + eddy current testing + cut length + facing & chamfering + final inspection + packing |
4. Process Details
| Process / Operation | tube forming |
| Outsource | Yes |
| Machine / Cell | TI |
| Machine / Cell No. | 1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Eddy current testing flaw detection failure | ECT software hanging issue faced while tube testing & re-started the PC | O |
| Machine | Weld Bond area Low Heat Penetration | During mill running tow bar & impeder unit serviced due to coolant flow blockage | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | eddy current testing |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 5 nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Weld Bond area Low Heat Penetration. |
| Why 2 | Impeder to strip edge EMF conductivity Low |
| Why 3 | Insufficient coolant flow to impeder core. |
| Why 4 | Impeder coolant flow line blockage due to oxide chips & sludge. |
| Why 5 | Coolant Flow line orifice diameter insufficient |
| Root Cause (Occurance) | Coolant Flow line orifice diameter insufficient |
Root Cause Analysis (Outflow)
| Why 1 | Eddy current testing flaw detection failure |
| Why 2 | ECT may accepted the Flaw product. |
| Why 3 | Momentary failure of Ect software TEST ON signal output |
| Why 4 | System software hang while ECT process period |
| Why 5 | |
| Root Cause (Outflow) | System software hang while ECT process period |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Tow bar inner diameter increased from 3mm to 6mm for free flow of coolant | Mr Maharajan | 21/12/2024 | 21/12/2024 | Completed |
| Outflow | System software hang while ECT process period. | Mr Maharajan | 18/12/2024 | 18/12/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | no change |
| Inspection Method | Other |
| Other Inspection Method | Eddy current testing |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 5 nos |
10. Evidance of Countermeasure
| Occurance (Before) |
Tow bar inner diameter 3mm which is blocked due to fine oxide chips interruption. 1277_Occurance_Before.png |
| Occurance (After) |
Tow bar inner diameter increased from 3mm to 6mm for free flow of coolant. 1277_Occurance_After.png |
| Outflow (Before) |
System software hang while ECT process period. 1277_Outflow_Before.png |
| Outflow (After) |
To prevent defect outflow, the ECT conveyor will be stopped after 3seconds in case of “ECT software hang & TEST signal not indicated 1277_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | no |
12. Document Review
| Documents | |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 20000 |
| Reason for submission | Reviewed 20000 no`s found ok |