QFR No - 7000869893
Defect Details
| NC No. | 7000869893 |
| NC Date | 11/10/2022 |
| NC Submission Date | |
| Part No. | 520FN04002 |
| Part Name | HOLDER CLUTCH |
| Supplier Name & Code | 100153-HINDUSTAN PRESSINGS PVT.LTD. |
| ETL Plant | 1135-ETL 7/10 P Nagar |
| Defect Details | DEEP MARK- |
1. Problem Description
| Defect Description | Dent issue on ID |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 250 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality.p1@hpplindia.com |
| Plant Head/CEO Email ID | spatil@hpplindia.com |
| MD Email ID | rakesh@hpplindia.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
9000
|
1000
|
0
|
0
|
0
|
10000
|
| Check Qty |
9000
|
0
|
0
|
0
|
0
|
9000
|
| NG Qty |
3072
|
0
|
0
|
0
|
0
|
3072
|
| Scrap | 0 |
| Rework | 3072 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done at ETL pantanagar. |
3. Process Flow
| Process Flow Description |
|---|
| 1. Raw material receipt and Inspection , 2. blanking and piercing, 3. sandering , 4. Vibro and Dryer, 5. Four Hole Chamfer, 6. Machining -Outsource, 7. Final Inspection 8. Oiling and packaging, 9. PDIR & Dispatch |
4. Process Details
| Process / Operation | Machining and material handling |
| Outsource | Yes |
| Machine / Cell | CNC Lathe |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | poor material finish or pitted material used | HR material is used as specified in drg, small dent mark on HR finish material are acceptable . | O |
| Man | poor material handling during inprocess and inspection | verified that bins are provided at each station and material stacking done neatly. | O |
| Tool | damaged tool used | tool condition was okay | O |
| Machine | tool mark during machining | verified, found okay | O |
| Method | Poor material handling during transportation from pune to aurangabad warehouse | after receipt at warehouse parts checked, dent on the parts observed. | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | visual checking |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | lot size |
7. Root Cause Analysis (Occurance)
| Why 1 | Dent mark on ID, OD & Face. |
| Why 2 | Dent marks are due to metal to metal contact and misshandling. |
| Why 3 | during transit from pune to aurangabad warehouse and loading-unloading these dent issue occured. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Due to poor material handling while transportation and loading -unloading heavy dent observed. |
Root Cause Analysis (Outflow)
| Why 1 | Dent mark on ID, OD & Face |
| Why 2 | 100% inspection done by final inspector but defect not detected. |
| Why 3 | Less awareness to inspector regarding small dents on face which is not detected visually easily. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Less awareness to inspector regarding small dents which are not detected visually easily. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Awareness given to the transportor about dent issue due to poor transportation. | Mr.Sontakke ( HPPL, Aurangabad) and transportor | 20/10/2022 | 18/10/2022 | Completed |
| Occurance | training given to the personel who are involved in loading and unloading at warehouse and personnel from HPPL PUNE | Mr. Hitendra Patil(HPPL) and Mr, Sontakke(HPPL) | 20/10/2022 | 18/10/2022 | Completed |
| Outflow | 1. Inspector training regarding all final inspection activities of 4002 holder,specially focussing on smaller dent on face. 2. 100% visual inspection at HPPL pune and 100% visual insection at HPPL aurangabad warehouse by experienced senior QA person for next 3 lot | Mr.Sontakke ( HPPL, Aurangabad) | 20/10/2022 | 18/10/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NA |
| Inspection Method | Other |
| Other Inspection Method | Visual checking |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | lot size |
10. Evidance of Countermeasure
| Occurance (Before) |
dent mark was observed due to misshandling and metal to metal contact during material transit 282_Occurance_Before.pdf |
| Occurance (After) |
Awareness given about dent issue due to poor transportation to the transportor. training on material loading unloading is given at HPPL PUNE and HPPL warehouse aurangabad. 282_Occurance_After.pdf |
| Outflow (Before) |
Less awareness to inspector regarding small dents on face which is not detected visually easily. 282_Outflow_Before.pdf |
| Outflow (After) |
1. Inspector training regarding all final inspection activities of 4002 holder,specially focussing on smaller dent on face.
2. 100% visual inspection at HPPL pune and 100% visual insection at HPPL aurangabad warehouse by experienced senior QA person for next 3 lot. 282_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | ok |