QFR No - 7001001044
Defect Details
| NC No. | 7001001044 |
| NC Date | 28/03/2024 |
| NC Submission Date | |
| Part No. | 53BKZ00102 |
| Part Name | RUBBER BUSH |
| Supplier Name & Code | 101023-FORES ELASTOMECH INDIA PVT. LT |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | DIMETER UNDERSIZE-OD undersize |
1. Problem Description
| Defect Description | OD 24.3+0.3/-0.3 observed undersize 23.70 mm. |
| Detection Stage | Receipt |
| Problem Severity | Fitment |
| NG Quantity | 17500 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | malani.pritam@foresgroup.com |
| Plant Head/CEO Email ID | singh.barinder@foresgroup.com |
| MD Email ID | swamy.pj@foresgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
17500
|
40000
|
0
|
0
|
0
|
57500
|
| Check Qty |
17500
|
40000
|
0
|
0
|
0
|
57500
|
| NG Qty |
10
|
0
|
0
|
0
|
0
|
10
|
| Scrap | 9 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % sorting of Fores stock |
3. Process Flow
| Process Flow Description |
|---|
| Material inward then forward to mixing department after that forward to molding process after that final inspection to standard packing. |
4. Process Details
| Process / Operation | Moulding |
| Outsource | No |
| Machine / Cell | Hyd 250 T |
| Machine / Cell No. | 250 T |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | buffing process | Buffing process at parting line | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Venier |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 50 |
7. Root Cause Analysis (Occurance)
| Why 1 | OD undersize |
| Why 2 | OD undersize on parting line |
| Why 3 | undersize at parting line de-flash portion |
| Why 4 | OD undersize due to buffing process at parting line |
| Why 5 | |
| Root Cause (Occurance) | OD undersize due to buffing process at parting line |
Root Cause Analysis (Outflow)
| Why 1 | OD undersize |
| Why 2 | Skipped from Inspection |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Skipped from Inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Buffing process removed. | Fores | 10/04/2024 | Pending |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Training given to Inspector & OPL displayed. |
| Inspection Method | Other |
| Other Inspection Method | vernier |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 50 |
10. Evidance of Countermeasure
| Occurance (Before) |
Parting line De-flashing by buffing wheel 728_Occurance_Before.jpg |
| Occurance (After) |
De-flashing process removed. 728_Occurance_After.jpg |
| Outflow (Before) |
OD inspection at sampling basis 728_Outflow_Before.jpg |
| Outflow (After) |
OD inspection at sampling basis, Sampling Quantity increase. 728_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Rubber bush |
12. Document Review
| Documents | |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |