QFR No - 7000867314
Defect Details
| NC No. | 7000867314 |
| NC Date | 30/09/2022 |
| NC Submission Date | |
| Part No. | 520BI00961 |
| Part Name | CALIPER BODY LH FINISHED -JD BLACK |
| Supplier Name & Code | 201092-PRANEEL INDUSTRIES |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | FITTMENT NOT OK.-Burr fold inside the 10 mm hole |
1. Problem Description
| Defect Description | Burr fold inside the 10 mm hole |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 131 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@praneelgroup.com |
| Plant Head/CEO Email ID | praneelindustries@rediiffmail.com |
| MD Email ID | anilpatil@praneelgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
0
|
0
|
500
|
1500
|
3000
|
| Check Qty |
1000
|
0
|
0
|
500
|
1500
|
3000
|
| NG Qty |
131
|
0
|
0
|
0
|
0
|
131
|
| Scrap | 131 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% stock inspected at ETL and supplier end and ok parts to line with identification mark |
3. Process Flow
| Process Flow Description |
|---|
| 1.Raw Material inspection 2. Powder Coating Process 3.Inspection of powder coating parts 4. Face milling 5. Drilling & Tapping 6.Deburring 7.Final Inspection 8.PDI 9.Packing & Dispatch |
4. Process Details
| Process / Operation | GDC Machine |
| Outsource | Yes |
| Machine / Cell | GDC Machine |
| Machine / Cell No. | GDC Machine 02 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Tool Wear out | Fittment issue | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Burr fold inside dia 10 mm |
| Why 2 | Core pin undersized |
| Why 3 | core pin wear out |
| Why 4 | core pin life not monitored |
| Why 5 | |
| Root Cause (Occurance) | Due to core pin wear out burr fold in dia 10mm |
Root Cause Analysis (Outflow)
| Why 1 | core pin wear out |
| Why 2 | core min life not monitored |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | due to core pin life not monitored core pin wear out leads into burr fold |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Core pin monitoring stared | QA | 10/10/2022 | 10/10/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Core pin inspection frequency change |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
CD Checking point not added in check sheet 266_Occurance_Before.pptx |
| Occurance (After) |
100% CD Checking added in Check sheet 266_Occurance_After.pptx |
| Outflow (Before) |
Core Pin life not monitored 266_Outflow_Before.pptx |
| Outflow (After) |
Core pin life monitoring started 266_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | GDC machine |
12. Document Review
| Documents | PMCheckSheet, InspCheckSheet |
| Specify Other Document | Q alert |
13. Effectiveness Of Action
| Reviewed Quantity | 10000 |
| Reason for submission | OK. |