QFR No - 7000966628
Defect Details
| NC No. | 7000966628 |
| NC Date | 12/12/2023 |
| NC Submission Date | |
| Part No. | B20702500O |
| Part Name | END CONNECTOR ASM ABS UNIT SIDE-ST.BR. |
| Supplier Name & Code | 101221-SUNREN AUTOMOTIVE PRIVATE LIMI |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | DAMAGES-dent and damage plating not ok |
1. Problem Description
| Defect Description | DAMAGES-dent and damage plating not ok |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 71 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | shivank@sunren.in |
| Plant Head/CEO Email ID | shivank@sunren.in |
| MD Email ID | subhashsaini@sunren.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
0
|
2000
|
3500
|
1500
|
2500
|
9500
|
| Check Qty |
0
|
2000
|
3500
|
1500
|
2500
|
9500
|
| NG Qty |
0
|
15
|
0
|
10
|
0
|
25
|
| Scrap | 0 |
| Rework | 25 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% Material Segregation |
3. Process Flow
| Process Flow Description |
|---|
| Forging-Centerless Grinding-Cylinder Drill-CNC1st-CNC2nd-Facing2nd-Neck Drill-Step Drill-Nipple Assy-Brazing-100% Visual Inspection-Bending-Final Inspection |
4. Process Details
| Process / Operation | Facing |
| Outsource | No |
| Machine / Cell | Facing Machine |
| Machine / Cell No. | 08 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Packaging Standard | Yes | O |
| Method | Due to handling i.e Metal to Metal contact | Yes | 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 | 10 |
7. Root Cause Analysis (Occurance)
| Why 1 | Dent & Damages |
| Why 2 | Due to small face width |
| Why 3 | Due to drawing req. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Due to small face width |
Root Cause Analysis (Outflow)
| Why 1 | Dent & Damages |
| Why 2 | Due to metal to metal contact |
| Why 3 | Due to poor handling |
| Why 4 | Due to packaging standard |
| Why 5 | |
| Root Cause (Outflow) | Due to packaging standard |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Face width should be increased and same to be cover in the drawing. | Sunren | 22/12/2023 | 22/12/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Additional Checkpoint added |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 10 |
10. Evidance of Countermeasure
| Occurance (Before) |
Face Width Diameter is 13.75 mm 612_Occurance_Before.pdf |
| Occurance (After) |
Face Width Diameter is 14.97 mm 612_Occurance_After.pdf |
| Outflow (Before) |
250 Nos / Polybag 612_Outflow_Before.png |
| Outflow (After) |
100 Nos / Polybag 612_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | B20702700O |
12. Document Review
| Documents | Drawing, ControlPlan, WISOP, ProcessFlowChart, PackingStd |
| Specify Other Document | ECN |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | No defect found in latest lot |