QFR No - 7000823246
Defect Details
| NC No. | 7000823246 |
| NC Date | 07/03/2022 |
| NC Submission Date | |
| Part No. | 520AE00100 |
| Part Name | CORE PLATE CAL 115 |
| Supplier Name & Code | 101145-STAR PROJECTS INDIA |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | FLATNESS NOT OK.-Flatness o/s 0.25~0.30 mm against 0.10 |
1. Problem Description
| Defect Description | Flatness oversize upto 0.25~0.30 mm against 0.10 mm |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 6000 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualityhead@starprojectsindia.com |
| Plant Head/CEO Email ID | engineering@starprojectsindia.com |
| MD Email ID | ishant@starprojectsindia.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
6000
|
192000
|
0
|
12000
|
0
|
210000
|
| Check Qty |
6000
|
36000
|
0
|
12000
|
0
|
54000
|
| NG Qty |
6000
|
0
|
0
|
0
|
0
|
6000
|
| Scrap | 6000 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material has been hold for 100% re-inspection the same with proper identification |
3. Process Flow
| Process Flow Description |
|---|
| Receipt of raw material- storage of raw material-Melting-PDC-1st Trimming -Shot blastng-2nd trimming-Barrelling-Shot blasting-Sound testing-Stress relieving -Final inspection & Packing-Storage & Dispatch |
4. Process Details
| Process / Operation | Packing & Dispatch |
| Outsource | No |
| Machine / Cell | Final inspection & Packing |
| Machine / Cell No. | Packing |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Poor handling during transit | Corrugated box of 5 ply using for packing ,chance of flatness issue | X |
| Method | 100% receiving gauging not done or gauge wear out | 100% gauging process done and also gauge verification doing as per defined frequency (F07/QAD(JFR) | O |
| Method | Heating process not done properly | Heating process adhered as per instruction (WI / PRM / 005,,F10/PRM(OLUM) | O |
| Method | Part not interlock with each other in heating fixture during heating process | Part proper locked in fixture at heating process by keshav | O |
| Man | unskilled | Uday pratap ,Baijnath was aware about the flatness issue | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | Per Lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Poor handling during transit ,chance of flatness issue |
| Why 2 | Existing Packing box not enough to avoid bend or flatness issue during transit . |
| Why 3 | No provision available in existing (Corrugated 5 ply) box to avoid flatness issues during transit. |
| Why 4 | Flatness & broken possibility not consider during material handling in transit |
| Why 5 | |
| Root Cause (Occurance) | Flatness & broken possibility not consider during material handling in transit |
Root Cause Analysis (Outflow)
| Why 1 | Check point not available at warehouse for flatness /Bend issue in core plate |
| Why 2 | Flatness & bend issue not considered while defined control plan |
| Why 3 | No criteria for defining the inspection parameters in control plan |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No criteria for defining the inspection parameters in control plan |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | PP corrugated foldable box to be introduced to avoid flatness and broken issue during transit | Bhim Singh | 25/04/2022 | 13/04/2022 | Completed |
| Occurance | Separator sheet to be introduced in box at top & bottom side to avoid bend & broken issue during transit | Bhim Singh | 03/12/2022 | 12/03/2022 | Completed |
| Outflow | 100% marking started after inspection at warehouse | Bhim Singh | 12/03/2022 | 12/03/2022 | Completed |
| Outflow | verification Check point to be added at warehouse | Bhim Singh | 03/12/2022 | 12/03/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% marking after gauging & inspection check point added at warehouse |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | each lot |
10. Evidance of Countermeasure
| Occurance (Before) |
5 ply corrugated box using for core plate packing ,No separator available at bottom & top side ,Change of damage & flatness out issue . 5_Occurance_Before.pdf |
| Occurance (After) |
1. 5 ply extra corrugated sheet provided in box at bottom & top side to avoid Flatness , broken & damage issue in core plate of K70 and as well as in other core plate .
2. PP Corrugated foldable box introduced instead of corrugated box 5 ply to avoid flatness ,Broken & damage issue during transit. 5_Occurance_After.pdf |
| Outflow (Before) |
1. No check point available at warehouse . 5_Outflow_Before.pdf |
| Outflow (After) |
1. Check point added with 100% marking after inspection at warehouse to detect flatness ,broken & damages issue in core plate 5_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | In all model of core plate |
12. Document Review
| Documents | WISOP, PackingStd |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 50000 |
| Reason for submission | ok |