QFR No - 7000933342
Defect Details
| NC No. | 7000933342 |
| NC Date | 28/07/2023 |
| NC Submission Date | |
| Part No. | F2DZ08810B |
| Part Name | K0PG FORK BOLT |
| Supplier Name & Code | 101037-SHREE PATEL INDUSTRIES |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | RUSTY-White rust |
1. Problem Description
| Defect Description | Rust |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 450 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality_spi@rediffmail.com |
| Plant Head/CEO Email ID | planthead_spi@rediffmail.com |
| MD Email ID | rspatel_spi@rediffmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
4480
|
0
|
0
|
0
|
0
|
4480
|
| Check Qty |
4480
|
0
|
0
|
0
|
0
|
4480
|
| NG Qty |
450
|
0
|
0
|
0
|
0
|
450
|
| Scrap | 450 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All suspected part checked and rejected part scraped. |
3. Process Flow
| Process Flow Description |
|---|
| 10. Incoming RM 20. Traub Turning 30. CNC 1st set up 40. CNC 2nd set up 50. Plating 60. Inspection 70. Packing & Dispatch |
4. Process Details
| Process / Operation | Plating |
| Outsource | No |
| Machine / Cell | Plating Tank |
| Machine / Cell No. | Tank No.1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Passivation bath tank | During process verification passivation bath tank capacity found ok . | O |
| Man | Unskilled Helper | Skill matrix verified and all the operators and helper found on required level 2 and level 3. | O |
| Machine | Current fluctuations of rectifier | No any current flucations during the process visit and last month recorded data verified for curren | O |
| Machine | Working on low temperature | Temperature monitoring data verified and found ok | O |
| Material | Plating Passivation | During process verification plating passivation pH found ok | O |
| Method | Material Handling | During process verification, input and output of parts storage is proper and handle done as per def | O |
| Method | Improper method of drying after plating | Manual drying procedure not properly maintain by the operator as per given WI of drying. | X |
| Man | Awareness of operator | Operator was aware with the defects which can be generate due to improper cleaning . | 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 | 100 |
7. Root Cause Analysis (Occurance)
| Why 1 | White rust/spot part reached at customer end. |
| Why 2 | White rust generated at plating |
| Why 3 | Plating part drying method improper. |
| Why 4 | Plating part hanging with jig and dry with Manual dryer |
| Why 5 | |
| Root Cause (Occurance) | While drying the part, the moisture and particle applied on the part catches white rust |
Root Cause Analysis (Outflow)
| Why 1 | Heavy rust observed customer end. |
| Why 2 | Inspector not detected dull plated part during final inspection . |
| Why 3 | Inspector was not aware about the defect. |
| Why 4 | No inspection std available at final inspection station. |
| Why 5 | |
| Root Cause (Outflow) | No inspection std available at final inspection station. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | We will improve the drying process by introduce industrial drying oven to remove all the moisture from the part. | SPI | 18/11/2023 | 04/08/2023 | Completed |
| Outflow | 1)Training provided to the final inspector about the problem and inspection std. 2)The visual inspection frequency increase till installation. 3)New fire wall station will be introduce at final inspection for this kind of defect. | SPI | 04/08/2023 | 04/08/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No |
| Inspection Method | Other |
| Other Inspection Method | No |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
10. Evidance of Countermeasure
| Occurance (Before) |
Hanger Photo 512_Occurance_Before.pdf |
| Occurance (After) |
Industrial drying oven will be introduce after plating for drying. 512_Occurance_After.pdf |
| Outflow (Before) |
No inspection std available at final inspection station 512_Outflow_Before.pdf |
| Outflow (After) |
1)Training provided to the final inspector about the problem and inspection std.
2)The visual inspection frequency increase till installation.
3)New fire wall station will be introduce at final inspection for this kind of defect. 512_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Fork Bolt K86A |
12. Document Review
| Documents | WISOP, InspCheckSheet |
| Specify Other Document | Yes |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |