QFR No - 7001030732
Defect Details
| NC No. | 7001030732 |
| NC Date | 05/07/2024 |
| NC Submission Date | |
| Part No. | B2QL00502O |
| Part Name | PISTON RETURN SPRING - K11, K2 |
| Supplier Name & Code | 101159-TECHNOMAT SPRINGS |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | SURFACE FINISH NOT OK-Rusty |
1. Problem Description
| Defect Description | Rusty |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 9000 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@technomatsprings.com |
| Plant Head/CEO Email ID | technomatsprings@gmail.com |
| MD Email ID | patilsadanand@technomatsprings.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
9000
|
0
|
0
|
15000
|
1000
|
25000
|
| Check Qty |
9000
|
0
|
0
|
15000
|
1000
|
25000
|
| NG Qty |
9000
|
0
|
0
|
0
|
0
|
9000
|
| Scrap | 0 |
| Rework | 9000 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Check available material. |
3. Process Flow
| Process Flow Description |
|---|
| RM > Coiling > SR1 > Grinding > Inspection > Final Inspection > Oiling > Packing > Dispatch |
4. Process Details
| Process / Operation | Oiling |
| Outsource | No |
| Machine / Cell | Oiling Machine |
| Machine / Cell No. | Oiling |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | UNSKILL OPERATOR | VERIFICATION OF SKILL MATRIX | O |
| Tool | NA | NA | O |
| Material | THE MATERIAL WAS STUCK AT OILING STAGE. | VERIFIED THE OILING STAGE,THE MATERIAL WAS STUCKED AT OILING STAGE. | X |
| Method | Improper Oiling Method | VERIFICATION OF METHOD | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 50 Nos |
7. Root Cause Analysis (Occurance)
| Why 1 | MATERIAL GET RUSTY |
| Why 2 | ALL MATERIAL OILING COVERAGE NOT DONE PROPERLY. |
| Why 3 | THE MATERIAL WAS STUCK AT OILING STAGE. |
| Why 4 | THE MATERIAL WAS NOT IMMEDIATELY OILED AFTER INSPECTION |
| Why 5 | THE OPERATOR WAS NOT AWARE ABOUT IMMEDIATELY OILING THE MATERIAL AFTER INSPECTION. |
| Root Cause (Occurance) | SPRING GET RUSTY DUE TO THE OPERATOR WAS NOT AWARE ABOUT IMMEDIATELY OILING THE MATERIAL AFTER INSPECTION. |
Root Cause Analysis (Outflow)
| Why 1 | MATERIAL GET RUSTY. |
| Why 2 | Defective parts escaped from inspector. |
| Why 3 | Inspection Done on sampling Basis. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspection Done on sampling Basis. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | After Grinding process we will do oiling and after that 100% final inspection. | Mr. Anuj | 25/07/2024 | 25/07/2024 | Completed |
| Outflow | We will do 100% inspection before material dispatch. | Mr. Anuj | 31/07/2024 | 25/07/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NA |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
After grinding process we are doing inspection and after that oiling. 903_Occurance_Before.pdf |
| Occurance (After) |
Grinding process we will do oiling and after that 100% final inspection. 903_Occurance_After.pdf |
| Outflow (Before) |
We were previously checking the material as per the sampling plan. 903_Outflow_Before.pdf |
| Outflow (After) |
We have started 100% inspection before dispatch. 903_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Oiling Mc |
12. Document Review
| Documents | WISOP |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 250 |
| Reason for submission | Improvement found in next lots |