QFR No - 7000844025
Defect Details
| NC No. | 7000844025 |
| NC Date | 22/06/2022 |
| NC Submission Date | |
| Part No. | 520JF00123 |
| Part Name | PISTON GROOVED |
| Supplier Name & Code | 100176-GKN SINTER METALS PRIVATE LIMI |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | RUSTY-Rusty |
1. Problem Description
| Defect Description | Quality issues of Rust, heavy dents on face due to loose packing (Without separator). |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 9716 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | yjs2ms4h4ye1mpfi2hldotw3.png |
Supplier Communication Details
| Quality Head Email ID | Manojkumar.Mali@gknpm.com |
| Plant Head/CEO Email ID | Manojkumar.Mali@gknpm.com |
| MD Email ID | Rajesh.Mirani@gknpm.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
46000
|
35000
|
0
|
25000
|
120000
|
226000
|
| Check Qty |
46000
|
35000
|
0
|
25000
|
120000
|
226000
|
| NG Qty |
9716
|
4612
|
0
|
2611
|
120000
|
136939
|
| Scrap | 9716 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All stock lying at ETL is under segregation. Quality Alert raised at Inhouse & Tier 2 Location .,Warehouse & Inhouse stock is under segregation |
3. Process Flow
| Process Flow Description |
|---|
| Forming - Sintering - Sizing -Machining - Oil dipping -Packing - PDI Inspection |
4. Process Details
| Process / Operation | Machining |
| Outsource | Yes |
| Machine / Cell | Oil dipping |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Parts exposed to the coolant mixed dewatering oil | Parts are found in contact with coolent mixed dewatering oil. | X |
| Material | Parts Metallurgy NG | Parts are OK to the metallurgical check and found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
7. Root Cause Analysis (Occurance)
| Why 1 | Parts exposed to the coolant mixed dewatering oil |
| Why 2 | Parts are in contact with coolant mixed dewatering oil |
| Why 3 | Parts carrying tray is resting at bottom side of the tank |
| Why 4 | Tray resting pads are at the bottom of the oil tank. |
| Why 5 | Tray resting pads are at the bottom of the oil tank. |
| Root Cause (Occurance) | Parts are in contact with coolant mixed dewatering oil |
Root Cause Analysis (Outflow)
| Why 1 | Skipped in IN process and Final inspection |
| Why 2 | Parts was found ok during inspection |
| Why 3 | Parts was rust free after final inspection |
| Why 4 | After final inspection , parts was ok at GKN pdi |
| Why 5 | Parts gets rusty after clearing the material from PDI |
| Root Cause (Outflow) | Parts gets rusty afeter clearing the material from PDI |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Refreshment training is provided to all operators and inspectors thru One Point lesson and quality alert. | Yogesh Wase | 10/06/2022 | 24/06/2022 | Completed |
| Occurance | 1. Dewatering tank design will be modified as stopper (Resting pads) for tray resting will placed upward to avoid the contact with coolant mixed oil. | Yogesh Wase | 24/06/2022 | 10/06/2022 | Completed |
| Outflow | Supervisor will re verify lots before dispatch after packing | Yogesh Wase | 10/06/2022 | 10/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NA |
| Inspection Method | Other |
| Other Inspection Method | NA |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
10. Evidance of Countermeasure
| Occurance (Before) |
Dewatering Tray Rest at the Bottom of the Oil Tank
Coolant mix oil found at same area
Draining frequency is Once/Day
Parts get affected due to coolant mix oil 182_Occurance_Before.xlsx |
| Occurance (After) |
Design of Dewatering Tank Is Changed
Tray Resting Area Fixed near to mid of tank,Frequency of coolant drain is changed by Once /Hr.Parts not affected due to coolant mix oil 182_Occurance_After.xlsx |
| Outflow (Before) |
NA 182_Outflow_Before.xlsx |
| Outflow (After) |
Supervisor will re verify lots before despatch after packing. 182_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | Found OK |