QFR No - 7000829982
Defect Details
| NC No. | 7000829982 |
| NC Date | 06/04/2022 |
| NC Submission Date | |
| Part No. | S2BY04007B |
| Part Name | CANISTER M/C, IMPREGNATED & COATED |
| Supplier Name & Code | 101032-ASM CASTINGS PRIVATE LIMITED ( |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | POWDER COATING NOT OK-POWDER COATING PEEL OFF |
1. Problem Description
| Defect Description | Canister Failed in Adhesion Test at Receipt |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 2000 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | bxvtf0xyugvyhemmx3w43yva.png |
Supplier Communication Details
| Quality Head Email ID | quality@asmcastings.in |
| Plant Head/CEO Email ID | skaul@asmcastings.in |
| MD Email ID | rajiv@asmcastings.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1200
|
0
|
0
|
1650
|
1000
|
3850
|
| Check Qty |
10
|
0
|
0
|
1650
|
1000
|
2660
|
| NG Qty |
0
|
0
|
0
|
1650
|
0
|
1650
|
| Scrap | 10 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Part Checked (10 Nos. each lot for Tape Test) and a chemical added in impregnation process as per M/S Ultraseal`s Recommendation (Sealant & Impregnation Unit Supplier) |
3. Process Flow
| Process Flow Description |
|---|
| R.M. Receiving - Casting - Fattling- CNC Machining - SPM Machining- Impregnation - Pin Pressing - Leakage Testing- Dry in Oven - Inspection & PDI - Packing - Dispatch |
4. Process Details
| Process / Operation | Impregnation |
| Outsource | No |
| Machine / Cell | Impregnation Unit |
| Machine / Cell No. | N/A |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Ra not maintained from Shot Blasting Machine | Ra Inspection & Cycle Time Verification in Shot Blasting Machine | X |
| Tool | Impregnation Unit not working adequately | Ring Test | X |
| Material | Impregnation Sealant not effective | Impregnation done at Customer End with Other Brand | O |
| Man | Operator not aware about process | Skill Matrix | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Tape Test |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | not detect |
7. Root Cause Analysis (Occurance)
| Why 1 | Powder Coating Peel off at customer end |
| Why 2 | bonding of Powder & Part could not be adequate |
| Why 3 | a layer of chemical sealant deposited at surface of part |
| Why 4 | Damaged /Old Mesh Used in Basket (mesh Not Changed Timely) |
| Why 5 | Mesh Changing Freq. Not decided. |
| Root Cause (Occurance) | Mesh Changing Freq. Not decided. |
Root Cause Analysis (Outflow)
| Why 1 | Can Not detected at ASM |
| Why 2 | Powder Coating at Outsource. (Customer /Supplier End) |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Powder Coating Out Source (Customer /Supplier) |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Qty. per Basket reduced from 600 nos. to 400 nos. per basket & added in Work Instruction. | Lalit Sharma | 30/07/2022 | 30/07/2022 | Completed |
| Occurance | Awareness Training Provided to Concerned person for Work Instruction ammedment. | Lalit Sharma | 02/08/2022 | 02/08/2022 | Completed |
| Occurance | Mesh Changing Freq. Added in Control Plan | Lalit Sharma | 01/02/2023 | Completed | |
| Occurance | Sealant Grade Changed from PC504 to IM3000 to improve Impregnation Quality. | Ultraseal. | 28/10/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Supervisor Verification for part Qty. in Basket as per W.I. |
| Inspection Method | Other |
| Other Inspection Method | as per w.i. |
| Check Point at Final Inspection | No |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 10 |
10. Evidance of Countermeasure
| Occurance (Before) |
01. Check Point not added in Work Instruction for qty per basket. 02. Sealent Grade Change from PC504 to IM3000 (Suggested by Impregnation Supplier) 47_Occurance_Before.png |
| Occurance (After) |
Work Instruction Updated for Qty. per Basket 47_Occurance_After.pdf |
| Outflow (Before) |
Awareness not evident to concern person for Qty. per basket. 47_Outflow_Before.jpg |
| Outflow (After) |
Awareness Training provided to concerned person 47_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | n/a |
12. Document Review
| Documents | WISOP |
| Specify Other Document | W.I |
13. Effectiveness Of Action
| Reviewed Quantity | 4000 |
| Reason for submission | No any Peel Off Reported after Action Taken |