QFR No - 7000870351
Defect Details
| NC No. | 7000870351 |
| NC Date | 12/10/2022 |
| 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 | Rusty |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 1614 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | Rajendra.Sethiya@gknpm.com |
| Plant Head/CEO Email ID | Pratik.Dharangaonkar@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 |
24000
|
0
|
0
|
40000
|
38000
|
102000
|
| Check Qty |
24000
|
0
|
0
|
40000
|
38000
|
102000
|
| NG Qty |
1696
|
0
|
0
|
0
|
0
|
1696
|
| Scrap | 1696 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All stock lying at ETL segregated for rusty issue, GKN FG stock quarantined & verified. Quality Alert raised at Tier 1 & Final inspection |
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 | Dewatering NG | Gemba conducted with CGT at Supplier End observed excess qty loaded for dewatering | X |
| Material | Parts Metallurgy NG | Parts are OK to the metallurgical check and found ok | O |
| Man | Skipped in inprocess and Final inspection | During inprocess inspection parts was rust free but possibility to rust further | O |
| Man | Untrained Operator | Operator skill matrix is ok | O |
| Method | Wrong DW oil grade used | Dewatering Oil grade DW27 is found with correct grdae | 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 are not completely dipped into dewatering tank |
| Why 2 | Excess part quantity taken for Oil dipping |
| Why 3 | Parts in tray carrying for dewatering is taken more |
| Why 4 | As per daily schedule of production, less capacity of dewatering |
| Why 5 | Only single dewatering tank was available |
| Root Cause (Occurance) | Excess part quantity taken for Oil dipping |
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 after clearing the material from PDI |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1.Oil dipping tanks will be marked with red , yellow and green oil leval. | B Avhad | 06/01/2023 | Completed | |
| Occurance | Refreshment training is provided to all operators and inspectors thru One Point lesson and quality alert. | B Avhad | 16/12/2022 | Completed | |
| Occurance | Addiitional one Dewatering Tank will be made available | B Avhad | 07/12/2022 | 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 | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 0 |
10. Evidance of Countermeasure
| Occurance (Before) |
No Marking/Identification on Oil Tank 284_Occurance_Before.pdf |
| Occurance (After) |
Oil dipping tanks will be marked with red , yellow and green oil level. 284_Occurance_After.pdf |
| Outflow (Before) |
NA 284_Outflow_Before.pdf |
| Outflow (After) |
NA 284_Outflow_After.pdf |
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 |