QFR No - 7001083193
Defect Details
| NC No. | 7001083193 |
| NC Date | 19/12/2024 |
| NC Submission Date | |
| Part No. | S2FF00802B |
| Part Name | GAS CAP- K1 RSA GDC CANISTER |
| Supplier Name & Code | 100827-SANJAY TECHNOPLAST PVT.LTD. |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | DIMETER UNDERSIZE-DIA. 38.0 OD UNDERSIZE |
1. Problem Description
| Defect Description | O/D 38.0 mm UNDERSIZE :- Gas Cap Side Leakage issue |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 2700 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | r5lpxjqnsj3bzlhliwtydmnl.png |
Supplier Communication Details
| Quality Head Email ID | qa.hodstplpn@sanjaygroup.in |
| Plant Head/CEO Email ID | praveen.singh@sanjaygroup.in |
| MD Email ID | accounts.pn@sanjaygroup.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
3200
|
0
|
0
|
25000
|
0
|
28200
|
| Check Qty |
3200
|
0
|
0
|
25000
|
0
|
28200
|
| NG Qty |
2700
|
0
|
0
|
2000
|
0
|
4700
|
| Scrap | 4700 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1-100 % inspection done at Customer end . 2- Accumulated material inspection at STPL end . 3-OPL Display 4-Sampling inspection increase - |
3. Process Flow
| Process Flow Description |
|---|
| M Inspection-RM Storage-Pre-Heating-Inj. Moulding-Deflashing-PDI-Packing-Logistics |
4. Process Details
| Process / Operation | Injection Moulding |
| Outsource | Yes |
| Machine / Cell | Moulding |
| Machine / Cell No. | FM110 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Injection holding time less | Verify with SPPS, Injection Holding time found less | O |
| Machine | Screw Position Less | Verify with SPPS material screw position found less due to srinkage obseved | O |
| Method | Inspection check point not defined | Dia 38 +/-0.1 mm not aided in PDI Reports | O |
| Method | Improper slider matching | Visual | X |
| Man | Unskilled Inspector | Dedicate inspector is available for inspection as per skill level | X |
| Machine | Barrel temprature low | Verify with SPPS Barrel temprature found low | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 10 |
7. Root Cause Analysis (Occurance)
| Why 1 | Leakage issue Observed in Gas cap |
| Why 2 | OD under size Specification -Dia 38 ±0.1 Observation -37.73 mm |
| Why 3 | Injection holding time & screw position less |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Injection holding time & screw position less |
Root Cause Analysis (Outflow)
| Why 1 | Leakage issue Observed in Gas cap |
| Why 2 | Not deduct during Pre-dispatch Inspection |
| Why 3 | Check Point was not defined in PDI inspection Check sheet for OD 38 ±0.1 mm |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Check Point was not defined in PDI inspection Check sheet for OD 38 ±0.1 mm . |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 1-Injection holding time increase 2-Barrel temprature increase 3-Injection Screw Position increase | Mr .Jitendar | 10/01/2025 | 29/12/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Check Point Defined in Pre-Dispatch Inspection Reports for OD 38 ±0.1 mm 100 % inspection . |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 10 |
10. Evidance of Countermeasure
| Occurance (Before) |
Unskilled Operator
Unskilled Inspector 1282_Occurance_Before.pdf |
| Occurance (After) |
1-Training Provided to Operators.
2-One Point Lesson Displayed 1282_Occurance_After.jpg |
| Outflow (Before) |
Injection holding time less
Barrel temperature low
Screw Position Less 1282_Outflow_Before.jpg |
| Outflow (After) |
1-Injection holding time increase
2-Barrel temperature increase
3-Injection Screw Position increase 1282_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Gas Cap BS 4 |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, JHCheckSheet, AuditCheckSheet, ProcessFlowChart, InspCheckSheet |
| Specify Other Document | OPL ,OJT |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |