QFR No - 7000910858
Defect Details
| NC No. | 7000910858 |
| NC Date | 22/04/2023 |
| NC Submission Date | |
| Part No. | S2DC03102B |
| Part Name | INNER DUST COVER K55G |
| Supplier Name & Code | 100990-JAIRAJ ANCILLARIES PVT LTD |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | BEND-found bend |
1. Problem Description
| Defect Description | During receipt inspection parts observed in bend condition?? Assembly fitment not possible. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 300 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | planthead.aurangabad@jairajgroup.com |
| Plant Head/CEO Email ID | vp@jairajgroup.com |
| MD Email ID | rajiv@jairajgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5600
|
0
|
0
|
3000
|
0
|
8600
|
| Check Qty |
5600
|
0
|
0
|
3000
|
0
|
8600
|
| NG Qty |
300
|
0
|
0
|
10
|
0
|
310
|
| Scrap | 310 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1. 100% inspection done at customer end & from all stages. 2. Defective parts are scrapped - 310 no`s - 27.04.2023 |
3. Process Flow
| Process Flow Description |
|---|
| RM Receiving- Inward Inspection- RM Issue- Master batch mixing - Injection molding -Deflashing - Final Inspection - Packing & Labelling - PDI & Dispatch |
4. Process Details
| Process / Operation | Injection Molding |
| Outsource | No |
| Machine / Cell | IMM |
| Machine / Cell No. | IMM-07 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Process parameter sheet not followed as per CP | Verified PPS . Found ok as per control plan | O |
| Tool | Tool PM not done | Verified & found ok | O |
| Material | RM Grade is not as per specification | Verified RMTC - Found ok - PPCP | O |
| Method | Stacking method In-adequately followed | Verified stacking height for IDC 3102 . Observed that 2 bags are more than specified stacking height | X |
| Machine | Injection pressure high/low comparing as per PPS | Verified injection pressure & found ok as per PPS | 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 | - |
7. Root Cause Analysis (Occurance)
| Why 1 | Part found bend due to stacking height weight |
| Why 2 | Stacking height is more than defined |
| Why 3 | In-adequate awareness about the stacking height resulting into bend |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | In-adequate awareness about the stacking height resulting into bend |
Root Cause Analysis (Outflow)
| Why 1 | Bend part not detected during PDI |
| Why 2 | Unable to detect the defect as PDI done on sampling basis only |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Unable to detect the defect as PDI done on sampling basis only |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | To check each & every bag on sampling basis during PDI | Amol Jagtap | 05/05/2023 | Completed | |
| Occurance | Awareness training about stacking height | Sachin Kulkarni | 05/05/2023 | Completed | |
| Outflow | OPL & Q alert to be displayed | Sachin Kulkarni | 05/05/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Check each & every bag on sampling basis during PDI |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | - |
10. Evidance of Countermeasure
| Occurance (Before) |
In-adequate Stacking height 431_Occurance_Before.jpg |
| Occurance (After) |
Proper stacking height 431_Occurance_After.jpg |
| Outflow (Before) |
PDI on sampling plan 431_Outflow_Before.pdf |
| Outflow (After) |
Each & every bag checked on sampling basis during PDI 431_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | - |
12. Document Review
| Documents | WISOP, InspCheckSheet |
| Specify Other Document | - |
13. Effectiveness Of Action
| Reviewed Quantity | 10 |
| Reason for submission | Corrective action parts submission. |