QFR No - 7000869422
Defect Details
| NC No. | 7000869422 |
| NC Date | 10/10/2022 |
| NC Submission Date | |
| Part No. | 520GR00102 |
| Part Name | MEMBRANE |
| Supplier Name & Code | 203807-ROOP POLYMERS LTD. |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | LEAKAGE-Leakage Due to non-filling |
1. Problem Description
| Defect Description | Leakage issue due to Non Filling at O Ring |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 9000 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | cwg20gmhnzlfu0ffjmtswljj.jpg |
Supplier Communication Details
| Quality Head Email ID | prem.singh@rooppolymers.com |
| Plant Head/CEO Email ID | ashish.grover@rooppolymers.com |
| MD Email ID | pbs.rawat@rooppolymers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
0
|
0
|
500
|
200
|
2700
|
| Check Qty |
2000
|
0
|
0
|
500
|
200
|
2700
|
| NG Qty |
12
|
0
|
0
|
5
|
0
|
17
|
| Scrap | 10 |
| Rework | 7 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Verify the available lot @ ETL as well as plant |
3. Process Flow
| Process Flow Description |
|---|
| Rubber Molding. |
4. Process Details
| Process / Operation | Molding |
| Outsource | No |
| Machine / Cell | 08 |
| Machine / Cell No. | 1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Material Loading Pattern Not Followed. | Found As per PCS. | O |
| Man | Less skilled operator | Skilled level 3 operator , as per skill matrix | O |
| Machine | Level of Machine Not OK | Level found within 0.025mm against spec 0.5mm | O |
| Material | Hardness of Material Excess | Found 55 Shore A | O |
| Tool | Leakage From Pocket & Plunger | Gap Observed in Plunger & Pocket. | X |
| Man | Less input weight placed by operator | Checked weight & 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 | Leakage issue due to Non Filling at O Ring area |
| Why 2 | Material Leakage from Transfer Pocket |
| Why 3 | Clearance observed in Pocket & Plunger corners. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Clearance observed in Pocket & Plunger corners. |
Root Cause Analysis (Outflow)
| Why 1 | Non filling @ O- ring Out flowed to customer. |
| Why 2 | Defective Part Mix-up with OK Parts |
| Why 3 | Small Red Bin Installed @ top of Inspection Table. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Small Red Bin Installed @ top of Inspection Table. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Pocket & Plunger welding & matching done to prevent Leakage | Daler Singh | 14/10/2022 | 14/10/2022 | Completed |
| Outflow | Training given to concerned Inspector | Rishabh Rastogi | 14/10/2022 | 14/10/2022 | Completed |
| Outflow | Red Bin Location Defined inside the Inspection table & Hole Given on top of the table to place the part into red bin. | Rishabh Rastogi | 13/10/2022 | 14/10/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | 100% Visual Inspection available. |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Clearance between Plunger & Pocket. 280_Occurance_Before.jpg |
| Occurance (After) |
Welding & Matching done on plunger to prevent Leakage 280_Occurance_After.jpg |
| Outflow (Before) |
Red Bin is above the table, NG Part Mixed with OK Parts. 280_Outflow_Before.jpg |
| Outflow (After) |
Red Bin placed Under rack, Hole Given for Part placing into red bin. 280_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Rubber Moulding |
12. Document Review
| Documents | WISOP |
| Specify Other Document | Tool History Card |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | Found OK |