QFR No - 7001036040
Defect Details
| NC No. | 7001036040 |
| NC Date | 23/07/2024 |
| NC Submission Date | |
| Part No. | B2EH08602O |
| Part Name | END CONNECTOR CALIPER SIDE N-TORQ |
| Supplier Name & Code | 101221-SUNREN AUTOMOTIVE PRIVATE LIMI |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | DENTS & DAMAGES-DENTS & DAMAGES |
1. Problem Description
| Defect Description | DENTS & DAMAGES-DENTS & DAMAGES |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 318 |
| 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 |
6000
|
9000
|
2500
|
1000
|
8000
|
26500
|
| Check Qty |
6000
|
9000
|
2500
|
1000
|
8000
|
26500
|
| NG Qty |
318
|
120
|
65
|
0
|
0
|
503
|
| Scrap | 0 |
| Rework | 503 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Re-Inspection For All The Suspected Qty. |
3. Process Flow
| Process Flow Description |
|---|
| Forging-Centerless Grinding-1st Cutting-2nd Cutting-Milling-Cross Drill-Facing 1st- Facing 2nd -Neck Drill-Cross Reamer-Chamfer-Air Cleaning-Pin Tray-Visual Inspection-Bending-Identification Marking-Plating-Final Inspection-Dispatch. |
4. Process Details
| Process / Operation | Centerless Grinding ,Milling, Cross Drill, |
| Outsource | No |
| Machine / Cell | 01 |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Wrong Method | Appropriate Method Not Followed | O |
| Man | Lack Of Awareness | Not Aware | 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 poor handling |
| Why 2 | Material Handling Method Not Followed |
| Why 3 | Lack of Awareness |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Material to Material Contact due to the poor handling. |
Root Cause Analysis (Outflow)
| Why 1 | Due to visual detection only. |
| Why 2 | Inspector was not aware. |
| Why 3 | Due to lack of Training |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Lack of Defect Awareness Training |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Material Handling Training Will be provided to the operators. | Amit | 01/08/2024 | 01/08/2024 | Completed |
| Outflow | Defect Awareness Training given to the inspectors. | Amit | 01/08/2024 | 01/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspectors will check the material as per the defect matrix. |
| 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) |
Poor Handling 957_Occurance_Before.jpg |
| Occurance (After) |
Material Handling Training Provided to the operators. 957_Occurance_After.pdf |
| Outflow (Before) |
Lack of Awareness Training 957_Outflow_Before.jpg |
| Outflow (After) |
Awareness training provided to the inspectors. 957_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Parts |
12. Document Review
| Documents | |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | found ok |