QFR No - 7001045569
Defect Details
| NC No. | 7001045569 |
| NC Date | 22/08/2024 |
| NC Submission Date | |
| Part No. | S1AB00612B |
| Part Name | ADJUSTER PLATED |
| Supplier Name & Code | 100782-NICE STEEL INDUSTRIES |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | PLATING NOT OK-Plating problem , milky, white rust |
1. Problem Description
| Defect Description | Plating defect i.e. White rust. |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 6000 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | ppc.nice@batragroup.biz |
| Plant Head/CEO Email ID | ho.nice@batragroup.biz |
| MD Email ID | hitesh@batragroup.biz |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
6000
|
0
|
0
|
1200
|
0
|
7200
|
| Check Qty |
6000
|
0
|
0
|
1200
|
0
|
7200
|
| NG Qty |
6000
|
0
|
0
|
1200
|
0
|
7200
|
| Scrap | 0 |
| Rework | 7200 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Re-plating to be done in all parts |
3. Process Flow
| Process Flow Description |
|---|
| 10 RECEIVING INSPECTION 20 STORAGE 30 BLANKING 40 1st BENDING ( `U` BENDING) 50 FINAL BENDING ( ROUNDING ) 60 MIG WELDING 70 FLAIRING 1st 80 FLAIRING 2nd 90 ID SIZING 100 SIDE GRINDING & BUFFING 110 REROUNDING 120 BROACHING 130 HEAD GRINDING 140 OUTSIDE MOVEMENT FOR PLATING 150 STORAGE & RQC INSP. OF PLATED MATERIAL 160 FINAL INSPECTION 170 PACKING & DISPATCH |
4. Process Details
| Process / Operation | 140 OUTSIDE MOVEMENT FOR PLATING |
| Outsource | Yes |
| Machine / Cell | Plating line |
| Machine / Cell No. | Plating Line |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Wrong tank used | Found ok | X |
| Material | Wrong chemical used | Chemical checked and found ok | X |
| Material | Chemical concertation was not ok | Testing done at internal lab and found ok | X |
| Method | Temperature specification | Temperature was 51 against specification 50 to 80 | O |
| Machine | Bath cleaning tank was not working | Checked and found ok | X |
| Machine | Zinc plating tank was not working | Checked and found ok | X |
| Method | Process sequence was wrong | Process and and found as per control plan | X |
| Method | SOP not followed | SOP followed and records verified | X |
| Man | Unskilled manpower | Skill matrix available | X |
| Machine | Oven was not ok | Oven is working but temperature was lower side of spec | 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 | sampling |
7. Root Cause Analysis (Occurance)
| Why 1 | Plating problem , milky, white rust |
| Why 2 | Passivation colure changed on part surface |
| Why 3 | Some moisture content was available at part surface |
| Why 4 | Part was not properly dry in oven |
| Why 5 | Temperature was in range but lower side because of One heater is not working |
| Root Cause (Occurance) | 1-Some moisture content was available at part surface due to part was not dry 2-Temperature was in range but lower side because of One heater is not working |
Root Cause Analysis (Outflow)
| Why 1 | Plating problem , milky, white rust |
| Why 2 | Final inspector not detect the ng part at Final inspection stage |
| Why 3 | Visual inspection was not done properly for shade mismatch |
| Why 4 | Checker was not understand the parts appearance status during visual inspection |
| Why 5 | Low lux level at inspection table |
| Root Cause (Outflow) | Checker was not understand the parts appearance status during visual inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Oven preventive maintenance revised and now maintenance will done on weekly basis instead monthly | Supplier | 25/08/2024 | 25/08/2024 | Completed |
| Occurance | Temperature parameter changed 50 TO 80 and increased temperature 70-80 to prevent the low temperature issue . | Supplier | 25/08/2024 | 25/08/2024 | Completed |
| Outflow | Cover holder bulb added at final inspection to increase the lux level . | Nice | 25/08/2024 | 25/08/2024 | Completed |
| Occurance | Lux level monitoring started | Supplier | 25/08/2024 | 25/08/2024 | Completed |
| Outflow | curing time increased Now 36 hrs from 24 hrs at Nice end | Nice | 24/08/2024 | 25/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Curing time incraesed |
| 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) |
NA 1030_Occurance_Before.png |
| Occurance (After) |
LUX LEVEL 1030_Occurance_After.png |
| Outflow (Before) |
NA 1030_Outflow_Before.png |
| Outflow (After) |
OVEN DAILY CHECKSHEET 1030_Outflow_After.png |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | PMCheckSheet, WISOP, JHCheckSheet |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |