QFR No - 7000873898
Defect Details
| NC No. | 7000873898 |
| NC Date | 02/11/2022 |
| NC Submission Date | |
| Part No. | 533BW00102 |
| Part Name | BUMP STOP |
| Supplier Name & Code | 101023-FORES ELASTOMECH INDIA PVT. LT |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | DAMAGES-Flashes and cut marks |
1. Problem Description
| Defect Description | Flash and cut mark |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 1140 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | 1y2tfrc3sjh55rzkgshxu2me.jpg |
Supplier Communication Details
| Quality Head Email ID | malani.pritam@foresgroup.com |
| Plant Head/CEO Email ID | singh.barinder@foresgroup.com |
| MD Email ID | swamy.pj@foresgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
20000
|
0
|
0
|
8000
|
0
|
28000
|
| Check Qty |
1140
|
0
|
0
|
8000
|
0
|
9140
|
| NG Qty |
1140
|
0
|
0
|
44
|
0
|
1184
|
| Scrap | 1184 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % sorting done at M/s ETL End with third party & also sorting done at Fores End. |
3. Process Flow
| Process Flow Description |
|---|
| Rubber & Chemical - Inward inspection - Rubber Mixing - Hardness inspection - Moulding - Visual inspection - Standard packing & Dispatch. |
4. Process Details
| Process / Operation | Rubber Moulding |
| Outsource | No |
| Machine / Cell | Moulding |
| Machine / Cell No. | Moulding |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Less or more temperature | PLC control / Machine stop if parameter not okay | O |
| Material | Wrong material used | We have checked hardness data last six month & found okay | O |
| Tool | Mould tool not okay | Mould leakage | X |
| Machine | Less or more curing time . | PLC control / Machine stop if parameter not okay | O |
| Man | Skipped from inspection . | NG parts found at customer End . | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 4000 |
7. Root Cause Analysis (Occurance)
| Why 1 | During deflashing operation . |
| Why 2 | Difficult to deflashing due to thick flash |
| Why 3 | Material flow not uniform due to mould leakage . |
| Why 4 | Mold parallelism not okay . |
| Why 5 | Mold tool PM frequency is Less . |
| Root Cause (Occurance) | Mold tool PM frequency is Less . |
Root Cause Analysis (Outflow)
| Why 1 | Flash & cut mark on part . |
| Why 2 | NG part found at customer end . |
| Why 3 | Inspector not aware . |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspector not aware . |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Training & awareness given to inspector. OPL display at inspection stage . | Mr Amar | 15/10/2022 | 14/10/2022 | Completed |
| Occurance | Mould PM frequency Increase . | Mr Ravi | 11/10/2022 | 11/10/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Visual inspection . |
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 4000 |
10. Evidance of Countermeasure
| Occurance (Before) |
Mould Leakage . 298_Occurance_Before.pdf |
| Occurance (After) |
Blue matching done & mould parallelism found okay.
Mould PM frequency Increase from 7000 shots to 5000 Shots . 298_Occurance_After.pdf |
| Outflow (Before) |
inspector not aware . 298_Outflow_Before.pdf |
| Outflow (After) |
Training & awareness given to inspector.
OPL display at inspection stage. 298_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applicable for all Bumps stop parts . |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | N/A |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | Found OK |