QFR No - 7001045639
Defect Details
| NC No. | 7001045639 |
| NC Date | 23/08/2024 |
| 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 thickness NG. |
1. Problem Description
| Defect Description | Plating thickness found 4 microns less. |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 5200 |
| Is Defect Repeatative? | Yes |
| 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 |
5200
|
0
|
0
|
1200
|
0
|
6400
|
| Check Qty |
5200
|
0
|
0
|
1200
|
0
|
6400
|
| NG Qty |
5200
|
0
|
0
|
1200
|
0
|
6400
|
| Scrap | 0 |
| Rework | 6400 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Re-plating to 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 | Plating |
| Outsource | Yes |
| Machine / Cell | Auto tank |
| Machine / Cell No. | tank |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Current was not proper flow at Zinc plating tanks | Checked and found hanger rusty | O |
| Method | SOP not followed | SOP followed and records verified | 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 |
| Machine | Bath cleaning tank was not working | Checked and found ok | X |
| Machine | Zinc plating tank was not working | Checked and found ok | X |
| Machine | Hanger hooks was rusty | Checked and found NG | O |
| Method | Process sequence was wrong | Process and and found as per control plan | X |
| Man | Unskilled manpower | Skill matrix available | X |
| Tool | Wrong tank used | Found ok | X |
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 | VISUAL |
7. Root Cause Analysis (Occurance)
| Why 1 | Plating thickness NG in part |
| Why 2 | Plating not done on part as per specification |
| Why 3 | Current was not properly flow on parts during plating |
| Why 4 | Hanger hooks was rusty |
| Why 5 | Zinc carbon was deposited at hanger hooks |
| Root Cause (Occurance) | 1-Zinc carbon was deposited at hanger hooks 2-Hanger hooks was rusty |
Root Cause Analysis (Outflow)
| Why 1 | Thickness NG part found at customer end |
| Why 2 | Final inspector not detect the ng part at Final inspection stage |
| Why 3 | PDI inspector check some sample parts during PDI |
| Why 4 | Part not checked 100% for plating thickness at PDI |
| Why 5 | As per sampling plan only sample basis parts checked during PDI |
| Root Cause (Outflow) | PDI inspector check some sample parts during PDI |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Daily hanger cleaning started instead of weekly maintenance | Supplier | 25/08/2024 | 25/08/2024 | Completed |
| Occurance | 20 spare hanger made for better quality part process | Supplier | 25/08/2024 | 25/08/2024 | Completed |
| Occurance | Supplier audit check sheet updated and Point will checked by Nice during Audit | Nice | 25/08/2024 | 25/08/2024 | Completed |
| Outflow | Sampling plan revised and sampling quantity increased | Supplier | 25/08/2024 | 25/08/2024 | Completed |
| Outflow | Sampling plan revised and sampling quantity increased at Nice incoming | Nice | 25/08/2024 | 25/08/2024 | Completed |
| Outflow | Training provided to Final inspector about defect | Nice & Supplier | 25/08/2024 | 25/08/2024 | Completed |
| Occurance | Hanger cleaning WI made | Supplier | 25/08/2024 | 25/08/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Sampling plan revised and sampling quantity increased |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 2time |
10. Evidance of Countermeasure
| Occurance (Before) |
NA 1037_Occurance_Before.png |
| Occurance (After) |
HANGER CLEANING WI 1037_Occurance_After.xlsx |
| Outflow (Before) |
NA 1037_Outflow_Before.png |
| Outflow (After) |
SAMPLING PLAN
SUPPLIER AUDIT REPORT 1037_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | WISOP, JHCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |