QFR No - 7001065590
Defect Details
| NC No. | 7001065590 |
| NC Date | 19/10/2024 |
| NC Submission Date | |
| Part No. | S3KJ00202B |
| Part Name | REBOUND STOP |
| Supplier Name & Code | 100990-JAIRAJ ANCILLARIES PVT LTD |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-I/D STEP SPE=12.50+0.10STPIN 12.50 N.PAS |
1. Problem Description
| Defect Description | NOT AS PER SPECIFICATION-I/D STEP SPE=12.50+0.10 STD PIN 12.50 NOT PASS |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 10000 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | planthead.aurangabad@jairajgroup.com |
| Plant Head/CEO Email ID | vp@jairajgroup.com |
| MD Email ID | rajiv@jairajgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
50000
|
0
|
0
|
2500
|
0
|
52500
|
| Check Qty |
50000
|
0
|
0
|
2500
|
0
|
52500
|
| NG Qty |
10200
|
0
|
0
|
428
|
0
|
10628
|
| Scrap | 10628 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All available material checked 100 % at ETL end and found 10200 no. defective out of 50000 no. checked. All available inhouse FG material checked 100% and found 428 no. defective parts out of 2500 no. checked. |
3. Process Flow
| Process Flow Description |
|---|
| Injection Moulding |
4. Process Details
| Process / Operation | Injection Moulding |
| Outsource | No |
| Machine / Cell | Injection Moulding Cell |
| Machine / Cell No. | IMM-01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | OCS & control plan not followed by Machine Operator | Verified as per CP & OCS found ok , as per standard specification | X |
| Tool | Mould Cooling Time High/low | Checked with CP & OCS and found OK as per specification | X |
| Machine | Barrel Temperature High/Low | Checked with CP & OCS and found OK as per specification | X |
| Material | RM Grade not as per CP | Check with MTC & found ok as per specification. | X |
| Man | Man Power does not aware about this defect . | Slight change in ID shift not identified by Process & final Inspector | O |
| Method | Checking method for OD checking | Verified as per CP/OCS and found checking method adequate for ID/OD Checking | X |
| Tool | Mould Cooling Water flow rate at Cooling Outlet | Verified as per Tool PM checksheet and found as per specification | X |
| Tool | Core & cavity centre not matched. | Verified as per tool design and found ID centre shift | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 |
7. Root Cause Analysis (Occurance)
| Why 1 | Defective parts are introduced. (Ie Step in ID ) |
| Why 2 | Due to mould core half loose observed with respect to cavity half. |
| Why 3 | Due to one Non operator Guide pin loosen in Core half. |
| Why 4 | Core & cavity half centre not matched. |
| Why 5 | |
| Root Cause (Occurance) | Core & cavity half centre not matched. |
Root Cause Analysis (Outflow)
| Why 1 | Defective parts are skipped from final inspection |
| Why 2 | Part dimensionally check on sampling basis |
| Why 3 | Operator not aware of this defect of step formation in ID. |
| Why 4 | On job training not given to Operator |
| Why 5 | Operator awareness of this defect is not evident |
| Root Cause (Outflow) | Operator awareness of this defect is not evident |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Mould check sheet follow before LPA / FPA. | Mr Ganesh Mhaske | 24/10/2024 | 24/10/2024 | Completed |
| Occurance | Verified the Guide Pins & Clamps during mould change over process. | Mr Ganesh Mhaske | 24/10/2024 | 24/10/2024 | Completed |
| Outflow | Defect matrix to display on work station. | Mr Sandip Rode | 26/10/2024 | 25/10/2024 | Completed |
| Outflow | On the job training given to In process & Firewall operator. | Mr Sandip Rode | 26/10/2024 | 25/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Inspection at firewall through Plug Gauge. |
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Mould Loading Unloading WI not evident for Core Cavity Alignment . 1174_Occurance_Before.pdf |
| Occurance (After) |
Training Record to Machine as well as In process Inspection Operator for Step Formation in ID. 1174_Occurance_After.pdf |
| Outflow (Before) |
Training Record and awareness not evident to final Inspection Operator for Step formation in ID. 1174_Outflow_Before.pdf |
| Outflow (After) |
Inspection standard made for final Inspector & Operator awareness 1174_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Rebound Stop S3KJ00302O |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | NIL |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | NO ID STEP OBSERVRED. |