QFR No - 7000991752
Defect Details
| NC No. | 7000991752 |
| NC Date | 02/03/2024 |
| NC Submission Date | |
| Part No. | 520DZ00212 |
| Part Name | FORK BOLT K60-(DS181012) |
| Supplier Name & Code | 101263-SINGLA PRECISION SCREWS |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | SALT SPRAY TEST FAIL-Plating Peel - Off SST fail in 24 Hours |
1. Problem Description
| Defect Description | Plating Peel - Off SST fail in 24 Hours |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 2000 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@singlaprecision.com |
| Plant Head/CEO Email ID | quality@singlaprecision.com |
| MD Email ID | aditya@singlaprecision.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
0
|
0
|
0
|
0
|
2000
|
| Check Qty |
2000
|
0
|
0
|
0
|
0
|
2000
|
| NG Qty |
2000
|
0
|
0
|
0
|
0
|
2000
|
| Scrap | 0 |
| Rework | 2000 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% LOT VERIFICATION BY SST AND PLATED PART MOVED IN CURING AREA AFTER PLATING |
3. Process Flow
| Process Flow Description |
|---|
| 1-R/M 2-TRUAB OPERATION 3-PUNCHING ,4-TRG GRINDING 5-ROLLING ,6-PLATING 7-FINAL INSPECTION , 8 FINAL INSPECTION 9-PACKING |
4. Process Details
| Process / Operation | PLATING |
| Outsource | No |
| Machine / Cell | PLATING |
| Machine / Cell No. | TANK NO-05 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | RM GRADE AND SIZE NOT OK | VALIDATION ANF FOUND OK | O |
| Method | LOT WISE SST NOT CHECKED | VALIDATION ANF FOUND NOT OK | X |
| Man | UNAWARENESS OF OPERATOR | VALIDATION AND FOUND OPERATOR SKILL LEVEL OK | O |
| Tool | N/A | N/A | O |
| Machine | MACHINE TANK NOT CLEAN AS PER PLAN | VALIDATION AND FOUND NOT OK | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | SST METHOD |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | As samp |
7. Root Cause Analysis (Occurance)
| Why 1 | SALT SPRAY TEST FAIL-Plating Peel - Off SST fail in 24 Hours |
| Why 2 | CLEANING NOT PROPERLY DONE |
| Why 3 | IN ANODIC CLEANING CURRENT NOT FLOWING PROPERLY. |
| Why 4 | CONTACT POINT FOUND LOOSE .THEREFORE, PROPER CURRENT NOT GET TO PARTS. |
| Why 5 | SCHEDULE MADE FOR ALL CONTACT POINT TO BE CHECK ON WEEKLY BASIS. |
| Root Cause (Occurance) | IN ANODIC CLEANING CURRENT NOT FLOWING PROPERLY. DUE TO LOOSE CONTACT POINT . THEREFORE, PROPER CURRENT NOT GET TO COMPONENTS SO CLEANING WAS NOT PROPER. . |
Root Cause Analysis (Outflow)
| Why 1 | SALT SPRAY TEST FAIL-Plating Peel - Off SST fail in 24 Hours |
| Why 2 | LOT WISE SST PLAN NOT PREPARED |
| Why 3 | AS PER PLAN SST NOT DONE LOT WISE |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | SST PLAN LOT WISE NOT PREPARED |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | CLEANING NOT PROPERLY DONE | GANESH MAURYA | 20/03/2024 | 19/03/2024 | Completed |
| Outflow | LOT WISE SST PLAN PREPARED CHECK SHEET | Mr GANESH MAURYA | 20/03/2024 | 19/03/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | SST CHECKING PLAN NOT EFFECTIVE |
| Inspection Method | Other |
| Other Inspection Method | SST REPORT |
| Check Point at Final Inspection | No |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | LOT WISE |
10. Evidance of Countermeasure
| Occurance (Before) |
SALT TEST REPORT UPDATE 708_Occurance_Before.pdf |
| Occurance (After) |
PLATING THIKNESS REPORT UPDATE 708_Occurance_After.pdf |
| Outflow (Before) |
SST PLAN NOT EFFECTIVE 708_Outflow_Before.xlsx |
| Outflow (After) |
LOT WISE SST REPORT PREPARED 708_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | ALL PLATING PART |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | SST PLAN UPDATE |
13. Effectiveness Of Action
| Reviewed Quantity | 1 |
| Reason for submission | SST requirement is 168hrs for White Rust & 480hrs for Red Rust, But the plan which you have attached the Red Rust hours mentioned as 400hrs. Secondly Third Party SST Testing done for only 240hrs. Third as the Frequency of your SST is 6 months, then what will be the method to ensure Plating is OK or Not of each lot. |