QFR No - 7000835500
Defect Details
| NC No. | 7000835500 |
| NC Date | 09/05/2022 |
| NC Submission Date | |
| Part No. | 520AE01502 |
| Part Name | CORE PLATE LML |
| Supplier Name & Code | 100959-AAR CEE ENGINEERING WORKS UNIT |
| ETL Plant | 1135-ETL 7/10 P Nagar |
| Defect Details | SHADE VARIATION-surface finish not ok |
1. Problem Description
| Defect Description | surface finish not ok |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 565 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qc@aarceeengg.com |
| Plant Head/CEO Email ID | planthead.diecasting@aarceeengg.com |
| MD Email ID | vaibhav.arora@aarceeengg.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5000
|
0
|
0
|
7500
|
8000
|
20500
|
| Check Qty |
5000
|
0
|
0
|
7500
|
8000
|
20500
|
| NG Qty |
500
|
0
|
0
|
50
|
0
|
550
|
| Scrap | 0 |
| Rework | 550 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Material segregated at the customer end (ETL end) & our end (AAR CEE end) NG parts to be reshot blasting. |
3. Process Flow
| Process Flow Description |
|---|
| 10. Receipt of Raw Material 20. Storage of Raw Material 30. Holding Cum Melting 40. PDC 50. Trimming 60. Shot Blasting 70. Barrelling 80. Sound Testing 90. Stress Relieving 100. Final Inspection & Packing 110. Storage & Dispatch |
4. Process Details
| Process / Operation | 60. Shot Blasting & 100. Final Inspection |
| Outsource | No |
| Machine / Cell | SHOT BLASTING MACHINE |
| Machine / Cell No. | SBM-02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Shot Blasting not done as per defined method in Control Plan | Operator not follow the method as defined in control plan | X |
| Man | At final inspection NG pieces skip | NG pieces skipped by Final Inspectors | X |
| Man | Operator not doing shot blasting as per defined method | Semi-skilled operator deputed by contractor | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10pcs |
7. Root Cause Analysis (Occurance)
| Why 1 | Shade variation surface finish is not ok due to shot blasting not being done correctly |
| Why 2 | Shot blasting is not done correctly due to the operator not following the defined method |
| Why 3 | Operator not following the defined method due to semi-skilled workforce deputed by the contractor |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Semi-skilled operator deputed by the contractor |
Root Cause Analysis (Outflow)
| Why 1 | The shade variation surface finish is not ok due to NG pieces skipped by final inspectors |
| Why 2 | NG pieces were skipped by final inspectors due to a semi-skilled workforce deputed by the contractor |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Semi-skilled operator deputed by the contractor |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | On job training to be given to the operators & also before deputing any worker induction training to be given | Ankit Gupta | 14/05/2022 | 14/05/2022 | Completed |
| Occurance | On job training to be given to the operators & also before deputing any worker induction training to be given | Ankit Gupta | 14/05/2022 | 14/05/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | no change |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 05 |
10. Evidance of Countermeasure
| Occurance (Before) |
No induction training was given to the newly joined manpower only format available but not adhered to. 97_Occurance_Before.pdf |
| Occurance (After) |
No induction training was given to the newly joined manpower only format available but not adhered to. 97_Occurance_After.pdf |
| Outflow (Before) |
On the job training is being given to the concerned persons & Induction training is being given to the shot blasting machine operator 97_Outflow_Before.pdf |
| Outflow (After) |
Induction Training is given to the quality inspector 97_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | All model |
12. Document Review
| Documents | WISOP |
| Specify Other Document | No other documents |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |