QFR No - 7001032025
Defect Details
| NC No. | 7001032025 |
| NC Date | 10/07/2024 |
| NC Submission Date | |
| Part No. | B20708200O |
| Part Name | END CON ASM ABS SIDE- ABS 2 FR MC K42CH |
| Supplier Name & Code | 101221-SUNREN AUTOMOTIVE PRIVATE LIMI |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | RUSTY-rusty |
1. Problem Description
| Defect Description | RUSTY-rusty |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 300 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | shivank@sunren.in |
| Plant Head/CEO Email ID | sanjayrana@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 |
2800
|
3800
|
800
|
500
|
1500
|
9400
|
| Check Qty |
2800
|
3800
|
800
|
500
|
1500
|
9400
|
| NG Qty |
300
|
0
|
0
|
0
|
0
|
300
|
| Scrap | 0 |
| Rework | 300 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Re-Plating |
3. Process Flow
| Process Flow Description |
|---|
| Plating |
4. Process Details
| Process / Operation | Plating |
| Outsource | Yes |
| Machine / Cell | 01 |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Wrong Method | Wrong Method Followed | O |
| Man | Lack of Knowledge | Skilled | X |
| Man | Lack Of Awareness | Training Required | 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 | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | Due to presence of water. |
| Why 2 | Due to no. of bends , in the part water gets accumulated at the bends. |
| Why 3 | Pressurized air not passed through the bends of the part. |
| Why 4 | Not Define in SOP. |
| Why 5 | Lack of Awareness |
| Root Cause (Occurance) | Pressurized Air not passes through the bends of the parts after plating operation. |
Root Cause Analysis (Outflow)
| Why 1 | Rust cannot be detected at the same time and takes time to occur. |
| Why 2 | Depends on storage conditions also. |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Rust takes time to occur and cannot be detected at the same time. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Rust Oil will be passed through the bend of the part after plating operation. | Krishna Plating | 30/07/2024 | 30/07/2024 | Completed |
| Occurance | Pressurized Air will be passed through the bends of the parts after plating operation. | Krishna Plating | 30/07/2024 | 30/07/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Rust oil will be passed through the end bend of the part after plating operation and it`s inspection. |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 5 |
10. Evidance of Countermeasure
| Occurance (Before) |
No Air Passes Through Bend After Plating Operation 932_Occurance_Before.jpg |
| Occurance (After) |
Air will be pass through bend after plating operation. 932_Occurance_After.jpeg |
| Outflow (Before) |
Rust Oil was applied over the surface of the part. 932_Outflow_Before.jpeg |
| Outflow (After) |
Rust oil will be pass through the bend of the part,. 932_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | B20707800O |
12. Document Review
| Documents | |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | ok |