QFR No - 7000922404
Defect Details
| NC No. | 7000922404 |
| NC Date | 14/06/2023 |
| NC Submission Date | |
| Part No. | 520KZ03002 |
| Part Name | BUSH (PLASTIC) |
| Supplier Name & Code | 101135-JAIRAJ ANCILLARIES PVT LTD |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | EXCESS MATERIAL-flashes ,Visual defects |
1. Problem Description
| Defect Description | Excess Flashes on material (visual defects). |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 1834 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality.sanand@jairajgroup.com |
| Plant Head/CEO Email ID | qms@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 |
15000
|
0
|
0
|
3000
|
0
|
18000
|
| Check Qty |
15000
|
0
|
0
|
3000
|
0
|
18000
|
| NG Qty |
1834
|
0
|
0
|
21
|
0
|
1855
|
| Scrap | 1855 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1. 100 % inspection done at ETL end. Checked all material from all stages 2. Defective parts are scrapped - 1855 qty - 16.06.2023 |
3. Process Flow
| Process Flow Description |
|---|
| RM Receiving - Inward Inspection - RM Issue to production - Pre-heating - Injection Molding - Degating - Final Inspection - Packing & Identification - PDI & Dispatch |
4. Process Details
| Process / Operation | Injection Molding |
| Outsource | No |
| Machine / Cell | Injection Molding Machine |
| Machine / Cell No. | IMM-07 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Process parameter not followed as per OCE/CP | Verified process parameter sheet . found ok as per control plan | O |
| Material | RM Grade is not as per specification | Supplier RMTC verified - RM found ok ( TPU) | O |
| Machine | Injection pressure/speed low ( lower than the specified limit) | Verified injection pressure & speed as per PPS , found ok | O |
| Man | In-adequate knowledge of product defect | Verified skill evaluation . Found operator is having in-adequate knowledge about the defect | X |
| Tool | Tool cavity wear out | Verified tool. Found two cavities out of 16 found wear out resulting uneven flash | X |
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 | 0 |
7. Root Cause Analysis (Occurance)
| Why 1 | Excess flash observed at ID side |
| Why 2 | two cavity found wear out resulting into uneven flash |
| Why 3 | In-adequate awareness about the mold polishing while moisture is present |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | In-adequate awareness about the mold polishing while moisture is present |
Root Cause Analysis (Outflow)
| Why 1 | Excess flash observed at ID side |
| Why 2 | Part is skipped to customer by operator |
| Why 3 | Operator is having inadequate awareness about defect |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Operator is having inadequate awareness about defect |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Part to be incorporated on quality gate for 200% inspection | Sachin K | 17/07/2023 | 17/07/2023 | Completed |
| Occurance | Mold polishing to be done as per defined frequency in procedure | Ganesh M | 24/06/2023 | 24/06/2023 | Completed |
| Outflow | On job training to be given to operator about part defect & it`s checking criteria | Sachin K | 24/06/2023 | 24/06/2023 | Completed |
| Outflow | 100% inspection of thickness by using Vernier caliper before dispatch | Amol C | 09/10/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection at both injection molding stage & final inspection stage |
| 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) |
Mold cavity wear 482_Occurance_Before.jpg |
| Occurance (After) |
PM Done 482_Occurance_After.pdf |
| Outflow (Before) |
OPL & Q-alert 482_Outflow_Before.pdf |
| Outflow (After) |
On job training record 482_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | - |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, WISOP |
| Specify Other Document | - |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Excess Flashes in bush (plastic) |