QFR No - 7000923409
Defect Details
| NC No. | 7000923409 |
| NC Date | 19/06/2023 |
| NC Submission Date | |
| Part No. | S2AB00512B |
| Part Name | ADJUSTER PLATED |
| Supplier Name & Code | 100782-NICE STEEL INDUSTRIES |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | PAINT PEEL OFF-platting peel off |
1. Problem Description
| Defect Description | Plating peel off |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 64 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | rg1cdvhmffno3if32xkq3udb.jpg |
Supplier Communication Details
| Quality Head Email ID | ppc.nice@batragroup.biz |
| Plant Head/CEO Email ID | ho.nice@batragroup.biz |
| MD Email ID | hitesh@batragroup.biz |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
0
|
0
|
2000
|
0
|
3000
|
| Check Qty |
1000
|
0
|
0
|
2000
|
0
|
3000
|
| NG Qty |
0
|
0
|
0
|
1
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All part visual inspection done |
3. Process Flow
| Process Flow Description |
|---|
| 10 RECEIVING INSPECTION 20 STORAGE 30 BLANKING 40 1st BENDING ( `U` BENDING) 50 FINAL BENDING ( ROUNDING ) 60 MIG WELDING 70 FLAIRING 80 ID SIZING 90 SIDE GRINDING 100 BROACHING 110 SINGLE GROOVE MATCHING 120 HEAD GRINDING 130 OUTSIDE MOVEMENT FOR PLATING 140 STORAGE & RQC INSP. OF PLATED MATERIAL 150 FINAL INSPECTION 160 PACKING & DISPATCH TO CUSTOMER |
4. Process Details
| Process / Operation | PLATING |
| Outsource | Yes |
| Machine / Cell | PLATING PROCESS |
| Machine / Cell No. | HANGER |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | HANGER INSPECTION | HANGER MAINTENANCE DONE ON MONTHLY BASIS BUT INSPECTION FREQUENCY WAS NOT DEFINED | O |
| Man | UNSKILL MANPOWER | SKILL MATRIX AVAILABLE | X |
| Tool | HANGER CONDITION WAS OK | CHECK AND FOUND HANGER HOOK DAMAGE | O |
| Machine | MACHINE CAPACITY WAS LOW | FOUND OK | X |
| Material | WRONG CHEMICAL USED | MTC VERFIFIED WITH TECHNICAL DATA SHEET | 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 | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | PLATING LAYER WAS DAMAGE IN PART |
| Why 2 | CHROME PLATING NOT DONE AS REQUIERD |
| Why 3 | CURRENT FLOW WAS NOT REGULAR |
| Why 4 | HANGER HOOKS WAS DAMAGE |
| Why 5 | NO DAILY HANGER INSPECTION SYSTEM WAS AVAILABLE ,ONLY HANGER MAINTENANCE DONE |
| Root Cause (Occurance) | 1-HANGER HOOKS WAS DAMAGE 2-NO DAILY HANGER INSPECTION SYSTEM WAS AVAILABLE ,ONLY HANGER MAINTENANCE DONE |
Root Cause Analysis (Outflow)
| Why 1 | DEFECTIVE PART FOUND AT CUSTOMER END |
| Why 2 | PARTS NOT DOUND DURING VISUAL INSPECTION |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | PARTS NOT DOUND DURING VISUAL INSPECTION |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | WEEKLY HANGER INSPECTION STARTED | VEEKAY IND. | 28/06/2023 | 25/06/2023 | Completed |
| Occurance | HANGER INSPECTION CHECKSHEET MADE AND FOLLOWED | VEEKAY | 27/06/2023 | 25/06/2023 | Completed |
| Outflow | 200% VISUAL INSPECTION STARTED | NICE | 26/06/2023 | 25/06/2023 | Completed |
| Outflow | QUALITY GATE IMPLEMENTED | NICE STEEL | 26/06/2023 | 25/06/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 200% VISUAL STARTED |
| Inspection Method | Other |
| Other Inspection Method | VISUAL |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | VISUAL |
10. Evidance of Countermeasure
| Occurance (Before) |
NO DAILY CHECKPOINT 486_Occurance_Before.pdf |
| Occurance (After) |
DAILY CHECKPOINT UPADTED 486_Occurance_After.xlsx |
| Outflow (Before) |
OPL 486_Outflow_Before.pdf |
| Outflow (After) |
OPL & TRAINING 486_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | HANGER MONITORING STARTED FOR OTHER PARTS |
12. Document Review
| Documents | JHCheckSheet |
| Specify Other Document | DAILY CHECKSHEET |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | ok |