QFR No - 7000987414
Defect Details
| NC No. | 7000987414 |
| NC Date | 20/02/2024 |
| NC Submission Date | |
| Part No. | S2FF00802B |
| Part Name | GAS CAP- K1 RSA GDC CANISTER |
| Supplier Name & Code | 100318-JAIRAJ GLOBAL |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | NOT AS PER SPECIFICATION-I/D Profile NG |
1. Problem Description
| Defect Description | Fitment Issue :- Air Hose Valve fitting I/D Profile N/G. |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 3200 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | agm@jairajgroup.com |
| Plant Head/CEO Email ID | vp@jairajgroup.com |
| MD Email ID | rajiv@jairajgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
6200
|
0
|
0
|
0
|
0
|
6200
|
| Check Qty |
6200
|
0
|
0
|
0
|
0
|
6200
|
| NG Qty |
6200
|
0
|
0
|
0
|
0
|
6200
|
| Scrap | 6200 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Immediate stop the supply and segregate all material which was lying in pipe line . |
3. Process Flow
| Process Flow Description |
|---|
| Material receiving- Incoming inspection- material storage- RM issue to production- Pre drying- injection molding - de-flashing- final inspection- labeling & Packing - Dispatch |
4. Process Details
| Process / Operation | Injection molding process |
| Outsource | No |
| Machine / Cell | injection molding machine |
| Machine / Cell No. | IMM 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Material not as per grade | Check with MTC | O |
| Method | Machine parameter not as per OCS | Machine parameter check with OCS | O |
| Man | Unskilled operator | Check with Attendance sheet and skill matrix | O |
| Machine | Machine tonnage not as per requirement | Check with Control plan | O |
| Tool | Tool dimension wear | major with instrument | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | ID profile of gas cap is NG |
| Why 2 | Gas cap ID was under size |
| Why 3 | Under size due to angle of tool pin is not as per specification |
| Why 4 | Tool pin wear out |
| Why 5 | |
| Root Cause (Occurance) | Due to tool pin was wear this problem was occurred. |
Root Cause Analysis (Outflow)
| Why 1 | ID profile of gas cap is NG |
| Why 2 | Not deduct at the time of setup inspection |
| Why 3 | this dimension was not mention in setup check sheet. |
| Why 4 | Check this dimension at the time of Lay out inspection. |
| Why 5 | |
| Root Cause (Outflow) | This dimension is not checked at the time of setup. It was checked in layout only. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Check point added in tool preventive maintenance check sheet for inspect pin at the time of preventive maintenance. | Brijesh | 08/03/2024 | Completed | |
| Outflow | Check point added in setup Check sheet. | Kabir | 08/03/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Checkpoint added in setup approval check sheet and PDIR to check One no`s of both cavity in every setup approval and PDIR. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
10. Evidance of Countermeasure
| Occurance (Before) |
Tool PM Check Sheet 686_Occurance_Before.pdf |
| Occurance (After) |
Updated Tool PM Check sheet 686_Occurance_After.pdf |
| Outflow (Before) |
Setup Approval Check sheet 686_Outflow_Before.pdf |
| Outflow (After) |
Updated Setup Approval Check Sheet 686_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Horizontal deploy on Gas cap BS4 Model |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, PFMEA, InspCheckSheet |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 10000 |
| Reason for submission | Its OK Now |