QFR No - 7000842723
Defect Details
| NC No. | 7000842723 |
| NC Date | 17/06/2022 |
| NC Submission Date | |
| Part No. | 53BHT00807 |
| Part Name | OUTER SPRING POWDER COATED-VAVE |
| Supplier Name & Code | 101048-STUMPP SCHUELE AND SOMAPPA SPR |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | POWDER COATING NOT OK-Powder coating Defects . |
1. Problem Description
| Defect Description | Powder coating Defects like White Spot, Heavy Hanger Marke, Pin Hole, Paint Uncover & Dry etc. |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 271 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | vipin.shukla@ssssprings.com |
| Plant Head/CEO Email ID | udham.singh@ssssprings.com |
| MD Email ID | rln@ssssprings.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1120
|
0
|
0
|
1120
|
0
|
2240
|
| Check Qty |
1120
|
0
|
0
|
1120
|
0
|
2240
|
| NG Qty |
8
|
0
|
0
|
0
|
0
|
8
|
| Scrap | 8 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Visual Inspection |
3. Process Flow
| Process Flow Description |
|---|
| Recipt & inspection - Storage of material - Winding - Stress Relieving-1 - Grinding - Shot peening - Stress Releiving-2 - Scragging - Length,e1,e2 sorting - powder coating - Final inspection - Packing |
4. Process Details
| Process / Operation | Powder Coating |
| Outsource | No |
| Machine / Cell | PC Line |
| Machine / Cell No. | Powder Coating |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | improper handling of the parts | Verified and found that parts fall down during hanging process and got dust accumulated | X |
| Method | OK and NG parts mix up during inspeciton | Inspected OK parts and Parts pending for inspection got mix up | X |
| Material | parts not cleaned during PT process | Process verified and found satisfactory PT process | O |
| Man | Unskilled person deputed for powder coated springs | Verified the skill level of the inspector and found OK | O |
| Machine | Powder coating gun parameters not as per specification | Verified all the machine parameters & found within specification | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Problem occured during powder coating process. |
| Why 2 | Dust accumulation during process |
| Why 3 | Few parts dropped down while loading/hanging to hangers & loaded again without cleaning. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Few parts dropped down while loading/hanging to hangers & loaded again without cleaning. |
Root Cause Analysis (Outflow)
| Why 1 | Defective part escaped through inspection |
| Why 2 | NG parts mixed up with OK parts. |
| Why 3 | Inspected OK parts and parts pending for inspection got mix up |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspected OK parts and parts pending for inspection got mix up |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Design of the hangers modified to avoid the fall of spring during hanging process | Mr Shashank | 23/06/2022 | Pending | |
| Outflow | Separator provided at inspection table to avoid the mix up of "Inspection finished parts" and "parts pending for inspection" | Mr. Shashank | 22/06/2022 | Pending |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Separator provided at inspection table to avoid the mix up of "Inspection finished parts" and "parts pending for inspection |
| Inspection Method | Pokayoke |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
No work instruction found for the treatment of fallen parts during hanging of springs during powder coating process 181_Occurance_Before.pdf |
| Occurance (After) |
Work instruction revised for the instructions on treatment of fallen parts 181_Occurance_After.pdf |
| Outflow (Before) |
Inspection finished parts and Inspection pending parts were kept together without separator. 181_Outflow_Before.png |
| Outflow (After) |
Separator provided to avoid accumulation at inspection table for the isnpected parts and inspection pending parts 181_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Horizontal deployment for Occurrence and Outflow actions for all OC springs |
12. Document Review
| Documents | WISOP |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |