QFR No - 7000849927
Defect Details
| NC No. | 7000849927 |
| NC Date | 19/07/2022 |
| NC Submission Date | |
| Part No. | 530DC00802 |
| Part Name | INNER DUST COVER |
| Supplier Name & Code | 101135-JAIRAJ ANCILLARIES PVT LTD |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | NOT AS PER LIMIT SAMPLE- Rubbing mark,scratch mark,visual Defect |
1. Problem Description
| Defect Description | Dent & Scratches |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 3537 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | djmfyappvchnnfd1btqarm1q.jpg |
Supplier Communication Details
| Quality Head Email ID | qms@jairajgroup.com |
| Plant Head/CEO Email ID | agm.sanand@jairajgroup.com |
| MD Email ID | rajiv@jairajgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
8500
|
0
|
0
|
2000
|
0
|
10500
|
| Check Qty |
8500
|
0
|
0
|
2000
|
0
|
10500
|
| NG Qty |
6910
|
0
|
0
|
235
|
0
|
7145
|
| Scrap | 235 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1. 100 % inspection done at ETL end & checked all the material from all stages. 2. Defective parts from WIP & FG stock are scrapped - Total scrap qty - 235 no`s , Dated on 21.07.2022 |
3. Process Flow
| Process Flow Description |
|---|
| RM Receiving - Inward Inspection - RM issue to Production - Injection Molding Process - Degating/Deflashing - Final Inspection - Packing & Identification -PDI - Dispatch |
4. Process Details
| Process / Operation | Injection molding |
| Outsource | No |
| Machine / Cell | IMM |
| Machine / Cell No. | IMM-07/E140T |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Process Parameter Not follow as per OCS/CP | Verifi ed Process parameter as per Control plan found OK | O |
| Machine | Machine change | Verified the mold machine matrix & found ok . Parts produced on defined machine as per matrix | O |
| Man | Unskilled Operator or Inspector Awareness about the defect | Shill evaluation done about the defect awareness - found ok | O |
| Material | RM Grade not as per specification | Supplier RMTC Verified and Third party Testing done from NABL approved lab for PPCP RM. | O |
| Tool | Tool Preventive Maintenance not done as per schedule. | Verified Tool PM schedule with actual PM- Found OK . Tool surface gloss found dull | X |
| Method | Material handling method is inappropriate | Verified handling method. Improvement required to avoid direct contact of parts with plastic bin | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | - |
7. Root Cause Analysis (Occurance)
| Why 1 | Method of handling is inappropriate at several stages for glossy parts resulting into visual defects |
| Why 2 | Less awareness about material handling for glossy parts as there is Direct contact of parts with plastic bin |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Less awareness about material handling for glossy parts |
Root Cause Analysis (Outflow)
| Why 1 | Defective parts skipped to customer |
| Why 2 | Defect is not detected at final inspection stage |
| Why 3 | Material handling after final inspection done inappropriate way resulting into visual defects |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Material handling after final inspection done inappropriate way resulting into visual defects |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Tool PM frequency to be verified and cavity gloss verification term added in PM Check sheet. | Mr.Nilesh Patil | 22/07/2022 | 22/07/2022 | Completed |
| Outflow | OPL & Q Alert to be Displayed at defect occurrence stage | Mr. Sachin Kulkarni | 22/07/2022 | 22/07/2022 | Completed |
| Occurance | Implement packing standard wrt material handling to avoid direct contact of parts with plastic bin | Mr. Sachin Kulkarni | 22/07/2022 | 22/07/2022 | Completed |
| Outflow | On Job Training to be given to concerned peoples | Mr. Sachin Kulkarni | 23/07/2022 | 23/07/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | - |
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | - |
10. Evidance of Countermeasure
| Occurance (Before) |
Material handling done in plastic bin 207_Occurance_Before.pdf |
| Occurance (After) |
Material handling improved as polybag implemented on machine . No use of plastic bin to avoid direct contact of parts with bin 207_Occurance_After.pdf |
| Outflow (Before) |
At final inspection stage, packing is inappropriate resulting visual defects as packing & dispatch activity to be carried out after this. 207_Outflow_Before.pdf |
| Outflow (After) |
Packing standard implemented at final inspection stage . After inspection , standard size of 100 no`s will be packed in stacking order with polybag. 207_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | - |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, PFMEA, WISOP, PackingStd, InspCheckSheet |
| Specify Other Document | - |
13. Effectiveness Of Action
| Reviewed Quantity | 2000 |
| Reason for submission | Verified improve lot and found effective. Also verified minor correction in arranging of material in packing improved material condition. |