QFR No - 7000933352
Defect Details
| NC No. | 7000933352 |
| NC Date | 28/07/2023 |
| NC Submission Date | |
| Part No. | S1AB00612B |
| Part Name | ADJUSTER PLATED |
| Supplier Name & Code | 100782-NICE STEEL INDUSTRIES |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | DIAMETER OVER SIZE-ID Oversize |
1. Problem Description
| Defect Description | ID oversize found 31.50 mm against specification (30.50~30.70) |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 1601 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
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 |
3000
|
4000
|
0
|
2000
|
2000
|
11000
|
| Check Qty |
3000
|
4000
|
0
|
2000
|
2000
|
11000
|
| NG Qty |
45
|
10
|
0
|
0
|
0
|
55
|
| Scrap | 55 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All material segregated and rejection part scarped |
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 1st 80 FLAIRING 2nd 90 ID SIZING 100 SIDE GRINDING & BUFFING 110 BROACHING 120 HEAD GRINDING 130 OUTSIDE MOVEMENT FOR PLATING 140 STORAGE & RQC INSP. OF PLATED MATERIAL 150 FINAL INSPECTION 160 PACKING & DISPATCH |
4. Process Details
| Process / Operation | ID sizing |
| Outsource | No |
| Machine / Cell | Press machine |
| Machine / Cell No. | Press machine |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Wrong material used | MTC verified and found ok | O |
| Tool | ID sizing punch | ID sizing punched checked and found NG | X |
| Method | SOP not followed | SOP available and followed | O |
| Man | Unskilled operator | Skill matrix available | O |
| Machine | Machine capacity was not ok | Machine capacity is ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | visual |
7. Root Cause Analysis (Occurance)
| Why 1 | ID oversize observed |
| Why 2 | id not maintained in part at upper size |
| Why 3 | leg was open during id sizing |
| Why 4 | Extra force on part by ID sizing punch |
| Why 5 | Minor welding bead stuck in part - |
| Root Cause (Occurance) | leg was open during id sizing |
Root Cause Analysis (Outflow)
| Why 1 | Defective part passed to customer |
| Why 2 | Could not detect during inspection |
| Why 3 | Only go side inspection done by gauge |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Only go side inspection done by gauge |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Re Round process added to close the open legs | Subodh Upadhyay | 20/08/2023 | 20/08/2023 | Completed |
| Outflow | Go and No Go gauge to be made | Nimit | 20/08/2023 | 20/08/2023 | Completed |
| Outflow | OPL dispalyed | Prahlad | 20/08/2023 | 20/08/2023 | Completed |
| Outflow | Training provided to all concern person | Nimit Prakash | 20/08/2023 | 20/08/2023 | Completed |
| Occurance | ID punch size decreased | Nimit Prakash | 20/08/2023 | 20/08/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | GO and No go gauge implemented |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
PFD DOCUEMNT 513_Occurance_Before.xlsx |
| Occurance (After) |
PFD DOCUEMNT REVISED 513_Occurance_After.jpeg |
| Outflow (Before) |
GAUGE 513_Outflow_Before.jpeg |
| Outflow (After) |
GAUGE REVISED 513_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | POWER PRESS |
12. Document Review
| Documents | ControlPlan, ProcessFlowChart |
| Specify Other Document | PFD AND CP UPDATED |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |