QFR No - 7000876117
Defect Details
| NC No. | 7000876117 |
| NC Date | 11/11/2022 |
| NC Submission Date | |
| Part No. | 520AE05702 |
| Part Name | CORE PLATE - SHINE & UNICORN |
| Supplier Name & Code | 101145-STAR PROJECTS INDIA |
| ETL Plant | 1132-ETL K-226/1 TRANSMISSION |
| Defect Details | FLATNESS NOT OK.-Ga gauge not qualify due to flatness o/s |
1. Problem Description
| Defect Description | Flatness Not OK -Not Qualify to gap gauge |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 9250 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualityhead@starprojectsindia.com |
| Plant Head/CEO Email ID | engineering@starprojectsindia.com |
| MD Email ID | ishant@starprojectsindia.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
15000
|
150000
|
0
|
0
|
0
|
165000
|
| Check Qty |
15000
|
0
|
0
|
0
|
0
|
15000
|
| NG Qty |
9250
|
0
|
0
|
0
|
0
|
9250
|
| Scrap | 9250 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All Material has been hold for 100% Re-Inspection for same with proper identification. |
3. Process Flow
| Process Flow Description |
|---|
| Receipt of Raw Material-Storage of raw material-Melting-PDC-1st Trimming-shot Blasting-1-2nd Trimming-Barreling-Shot Blasting-2-Sound Testing-Stress relieving-Final Inspection & packing-Storage & Dispatch. |
4. Process Details
| Process / Operation | Stress Relieving |
| Outsource | No |
| Machine / Cell | Oven-02 |
| Machine / Cell No. | No |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Lug Matching Sequence | Lug Matching Sequence was Disturb | X |
| Man | Negligency Done by Inspector | Semi-Skilled operator was there | X |
| Tool | Receiving Gauge Wear out | Base Size and lug size of slip gauge found at higher point. | X |
| Method | Heating parameter disturb | Heating Parameter Observed 261°C against 270±20°C | O |
| Method | Receiving Gauge Validation Plan | Receving Gauge Validation Plan was Available but not done Properly | 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 | Per Lot |
7. Root Cause Analysis (Occurance)
| Why 1 | Flatness Found NG in core Plate C-101 |
| Why 2 | Due to Lug Matching Sequence was Disturb |
| Why 3 | Due to improper material handling during heating |
| Why 4 | Semi-Skilled operator was there |
| Why 5 | |
| Root Cause (Occurance) | Due to Lug Matching Sequence was disturbed |
Root Cause Analysis (Outflow)
| Why 1 | 100% parts was checked by receiving gauge |
| Why 2 | Receiving gauge was not detected the defective parts |
| Why 3 | Due to Base Size and lug size of Receiving gauge found at higher point |
| Why 4 | Receiving Gauge wear out |
| Why 5 | |
| Root Cause (Outflow) | Receiving Gauge wear out |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Receiving gauge validation plan has been updated and adhered | Ajay Malik | 10/11/2022 | 10/11/2022 | Completed |
| Outflow | Training has been provided to Inspectors & Operator | Ajay malik | 09/11/2022 | 09/11/2022 | Completed |
| Occurance | Receiving Gauge Rectification Has been done.. | Ajay Malik | 10/11/2022 | 10/11/2022 | Completed |
| Occurance | Check Point added in heating WI | Ajay Malik | 10/11/2022 | 10/11/2022 | Completed |
| Outflow | Inspectior & Gauger Identification Code has been marked on every Boxes | Ajay Malik | 10/11/2022 | 10/11/2022 | Completed |
| Outflow | 100% marking Implemented on every lot | Ajay malik | 10/11/2022 | 10/11/2022 | Completed |
| Outflow | Quality Alert made and displayed at concerned area | Ajay malik | 09/11/2022 | 09/11/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspector & Gauger Identification Code has been marked on every Boxes With 100% Marking on parts |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | Per Lot |
10. Evidance of Countermeasure
| Occurance (Before) |
Check Point Not added in Heating WI 300_Occurance_Before.pdf |
| Occurance (After) |
Check Point added in Heating WI 300_Occurance_After.pdf |
| Outflow (Before) |
No Check Point Available for Proper Identification 300_Outflow_Before.pdf |
| Outflow (After) |
Inspector & Gauger Identification Code has been marked on every Boxes. 300_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | In All Model of Core Plate |
12. Document Review
| Documents | WISOP |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 5000 |
| Reason for submission | OK |