QFR No - 7000923677
Defect Details
| NC No. | 7000923677 |
| NC Date | 21/06/2023 |
| NC Submission Date | |
| Part No. | S2DP02902B |
| Part Name | EXTENSION K55G |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | RUSTY-Rusty |
1. Problem Description
| Defect Description | Material rusty |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 1090 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@apw3.co.in |
| Plant Head/CEO Email ID | kurund.ma@sharp-engineers.com |
| MD Email ID | urkhandelwal@sharp-engineers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5000
|
5000
|
0
|
1000
|
0
|
11000
|
| Check Qty |
5000
|
5000
|
0
|
1000
|
0
|
11000
|
| NG Qty |
1090
|
0
|
0
|
0
|
0
|
1090
|
| Scrap | 0 |
| Rework | 1060 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation done at WIP and FG and defective part removed from ok part. |
3. Process Flow
| Process Flow Description |
|---|
| 10) RM Inward 20) Storage 30) Material Issue 40) Parting & Drilling 50) ID Chamfer 60) Tapping 70) OD grinding 80) Final Inspection 90) Pre-dispatch inspection100) Packing & dispatch |
4. Process Details
| Process / Operation | Storage (Warehouse) |
| Outsource | Yes |
| Machine / Cell | NA |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Improper preventive maintenance | Preventive maintenance plan evident as per P/MNT/01 and being followed as per F/MNT/07 | O |
| Method | Material Handling( Material should be store on the pallet at warehouse) | Material kept on ground floor instead of pallet. | X |
| Tool | Insert/Tool/Drill worn out | Tool life monitoring as per defined tool life monitoring. | O |
| Material | Incorrect Raw Material | Material observed as per customer requirement Ø16.10 EN1A , MTC verified as per drawing specificatio | O |
| Man | Un-skilled Operator | Stage wise skill matrix and operator license are evident as per F/HR/06 | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Warehouse storage |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | Bag to Bag |
7. Root Cause Analysis (Occurance)
| Why 1 | Extension K55 Rusty |
| Why 2 | Material storage on the ground floor |
| Why 3 | Pallet not available. |
| Why 4 | Improper material storage by old transporter (Mumbai-Gujrat transport) |
| Why 5 | |
| Root Cause (Occurance) | Material storage on the ground floor, Pallet not available. (Mumbai-Gujrat transport) |
Root Cause Analysis (Outflow)
| Why 1 | Extension K55 Rusty part reached to ETL |
| Why 2 | RP oil dried after 20 days of oil application |
| Why 3 | Rust preventive oil PANOL RP DW 68 being used |
| Why 4 | Defined by system. |
| Why 5 | |
| Root Cause (Outflow) | Rust preventive oil PANOL RP DW 68 being used, less life of rust preventive oil(Only 15 days after oil application) |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Rust preventive oil VORSTAB is being used, excess life of rust preventive oil. (@1 month) | Mr. Shaikh L.N. | 04/07/2023 | 04/07/2023 | Completed |
| Occurance | Proper storage identified at warehouse material and provided pallet for storage | Mr. Shaikh L.N. | 04/07/2023 | 04/07/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | RP oil has been changed |
| Inspection Method | Other |
| Other Inspection Method | Visually |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1:1 |
10. Evidance of Countermeasure
| Occurance (Before) |
Material storage on the ground floor, Pallet not available. (Mumbai-Gujrat transport) 490_Occurance_Before.pptx |
| Occurance (After) |
Pallet made available. (Anjali logistic ) 490_Occurance_After.pptx |
| Outflow (Before) |
Rust preventive oil PANOL RP DW 68 being used, less life of rust preventive oil(Only 15 days after oil application) 490_Outflow_Before.pptx |
| Outflow (After) |
Rust preventive oil VORSTAB is being used, excess life of rust preventive oil. (@1 month) 490_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | No rust observed in fresh lots. |