QFR No - 7001045399
Defect Details
| NC No. | 7001045399 |
| NC Date | 21/08/2024 |
| NC Submission Date | |
| Part No. | F2DZ08810B |
| Part Name | K0PG FORK BOLT |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | PLATING NOT OK-Plating milky white ,black spot |
1. Problem Description
| Defect Description | Plating defect i.e. milky white and Black spot . |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 721 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@apw3.co.in |
| Plant Head/CEO Email ID | kurund.ma@sharp-engineers.com |
| MD Email ID | urkhandelwal@sharp-engineers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
7200
|
9800
|
0
|
5000
|
0
|
22000
|
| Check Qty |
7200
|
9800
|
0
|
5000
|
0
|
22000
|
| NG Qty |
780
|
10
|
0
|
0
|
0
|
790
|
| Scrap | 0 |
| Rework | 780 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All pipeline material segregated at customer end, warehouse and FG stock |
3. Process Flow
| Process Flow Description |
|---|
| Incoming RM-Parting-CNC 1st-CNC 2nd-Plating-Final Inspection-PDI-Packing and forwarding |
4. Process Details
| Process / Operation | Plating |
| Outsource | Yes |
| Machine / Cell | Plating cell |
| Machine / Cell No. | Plating cell |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Process Parameter wrong | Found as per control plan | O |
| Method | Jig not clean properly | Cleaned properly at defined frequency | O |
| Method | Part not Loaded properly | Part loaded properly as per SOP | O |
| Method | Curing Time not given | Curing not done | X |
| Method | Inspection frequency | Inspection frequency less | X |
| Tool | Tool change | No change | O |
| Material | PH variation | PH found OK | O |
| Machine | Tank not discarded | found ok | O |
| Man | New manpower | Manpower not changed | O |
| Material | Incorrect Chemical | Found ok | O |
| Man | Unskilled Operator | Skill manpower available as per skill matrix | O |
| Material | Variation in Chemical | Chemical found ok | 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 | 10 nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Plating Not ok |
| Why 2 | Found Rusty, black spot |
| Why 3 | Part dispatched without curing process |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Curing process not done |
Root Cause Analysis (Outflow)
| Why 1 | Plating Not ok |
| Why 2 | Found Rusty, black spot |
| Why 3 | Skipped from final inspection stage |
| Why 4 | Inspection frequency is low |
| Why 5 | |
| Root Cause (Outflow) | Inspection frequency is low |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Onjob training given to Operator about process awareness | Mr. Pradeep Bhagwat | 16/08/2024 | 16/08/2024 | Completed |
| Outflow | Inspection frequency increased from 10nos per lot to 20nos per lot | Mr. Pradeep bhagwat | 16/08/2024 | 16/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Inspection frequency inscreased |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Curing process SOP not displayed 1029_Occurance_Before.jpg |
| Occurance (After) |
Curing process SOP displayd 1029_Occurance_After.jpg |
| Outflow (Before) |
Inspection frequency less 1029_Outflow_Before.jpg |
| Outflow (After) |
Onjob training given to operator and inspector for defect awareness and inspection frequency 20nos per lot 1029_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Plating cell |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | PLATING NOT OK-Plating milky white ,black spot. |