QFR No - 7001054564
Defect Details
| NC No. | 7001054564 |
| NC Date | 18/09/2024 |
| NC Submission Date | |
| Part No. | 520HN00102 |
| Part Name | OIL SEAL |
| Supplier Name & Code | 101062-FREUDENBERG-NOK PRIVATE LIMITE |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | RUSTY-Rusty material Recieved |
1. Problem Description
| Defect Description | Rusty Found in oil seal K0LA (Insert metal) . |
| Detection Stage | Receipt |
| Problem Severity | Function |
| NG Quantity | 10000 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | Manpreet.Rahi@fst.com |
| Plant Head/CEO Email ID | Vishal.Inge@fst.com |
| MD Email ID | anand.thiagarajan@fst.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
82000
|
112000
|
0
|
176000
|
0
|
370000
|
| Check Qty |
82000
|
112000
|
0
|
176000
|
0
|
370000
|
| NG Qty |
40000
|
42000
|
0
|
0
|
0
|
82000
|
| Scrap | 42000 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% visual reverification for rust issue & OK identification on label of box |
3. Process Flow
| Process Flow Description |
|---|
| Moulding-->Trimming--Greasing--Inspection & packing |
4. Process Details
| Process / Operation | Moulding to FG |
| Outsource | No |
| Machine / Cell | Compression Moulding |
| Machine / Cell No. | Compression Moulding |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Part storage in incorrect packing | Part packaging found as per defined packing standard | O |
| Material | Humidity impact on metal part at storage condition with current packing | Humidity observed high due to rainy season & moisture impact on metal part with current polybag | X |
| Method | Metal part kept in open condition at WIP stage (before moulding) | Metal part storage observed in closed polybag after treatment | O |
| Method | Phosphating process skipped | batch production observe din process with tag on each stage | O |
| Material | Rust on input metal parts | Rust preventive oil seal & phosphating process defined for metal treatment | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visually detected |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Rust on metal area in oil seal |
| Why 2 | Moisture impacted on open metal area |
| Why 3 | Humidity impacted open metal area in oil seal |
| Why 4 | Current polybag used for oil seal does not have rust prevention controls. |
| Why 5 | Inadequate polybag defined for oil seal packing |
| Root Cause (Occurance) | Current polybag used for oil seal does not have rust prevention controls due to Inadequate polybag defined for oil seal packing |
Root Cause Analysis (Outflow)
| Why 1 | Rust on metal area in oil seal not detected @FNI |
| Why 2 | Delayed failure |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Delayed failure |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | VCI polybag to be used instead of normal polybag | FNI | 25/10/2024 | 10/10/2024 | Completed |
| Outflow | Training & education to operators | FNI | 18/09/2024 | 18/09/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No change |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | No |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Normal white polybag used 1099_Occurance_Before.png |
| Occurance (After) |
VCI polybag instead of normal 1099_Occurance_After.png |
| Outflow (Before) |
Rust defect was not updated 1099_Outflow_Before.pdf |
| Outflow (After) |
Defect sheet updated with rust defect 1099_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | WISOP, PackingStd |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Rusty Found in oil seal K0LA (Insert metal) |