QFR No - 8000779369
Defect Details
| NC No. | 8000779369 |
| NC Date | 10/03/2022 |
| NC Submission Date | |
| Part No. | S1AB00612B |
| Part Name | ADJUSTER PLATED |
| Supplier Name & Code | 100782-NICE STEEL INDUSTRIES |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | MIX UP OTHER MODEL-WRONG PART NOT USING K0PG REAR MODEL |
1. Problem Description
| Defect Description | adjuster small size part mix up not using K0PG Rear model |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 8 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | y1hynmfxkooqo3rg1jwpcn4h.xlsx |
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 |
0
|
0
|
0
|
1000
|
2000
|
3000
|
| Check Qty |
0
|
0
|
0
|
1000
|
2000
|
3000
|
| NG Qty |
0
|
0
|
0
|
1
|
0
|
1
|
| Scrap | 0 |
| Rework | 1 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% MATERIAL CHECKED AT WIP AND FINISH GOOD . |
3. Process Flow
| Process Flow Description |
|---|
| PROCESS SEQUENCE CHART 10 RECEIVING INSPECTION 20 STORAGE 30 BLANKING 40 1st BENDING ( `U` BENDING) 50 FINAL BENDING ( ROUNDING ) 60 MIG WELDING 70 FLAIRING 80 ID SIZING 90 SIDE GRINDING 100 BROACHING 110 HEAD GRINDING & BUFFING 120 OUTSIDE MOVEMENT FOR PLATING 130 STORAGE & RQC INSP. OF PLATED MATERIAL 140 FINAL INSPECTION 150 PACKING & DISPATCH |
4. Process Details
| Process / Operation | 120 OUTSIDE MOVEMENT FOR PLATING |
| Outsource | No |
| Machine / Cell | DISPATCH FOR PLATING |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Only sampling base |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 100 pcs |
7. Root Cause Analysis (Occurance)
| Why 1 | Wrong model part dispatch to customer |
| Why 2 | Plating done in wrong model part |
| Why 3 | Wrong model part mix-up during dispatch time (Outsource plating) |
| Why 4 | Only sampling Inspection done before dispatch to plating supplier for plating |
| Why 5 | |
| Root Cause (Occurance) | Inspection system was not define before plating |
Root Cause Analysis (Outflow)
| Why 1 | Wrong model part passed to customer |
| Why 2 | Part could not detect during inspection time |
| Why 3 | Same id spec in both part so part easily qualify in gauge during inspection |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Same id spec in both part so part easily qualify in gauge during inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | One Point lesson displayed at PDI stage | Nice Team | 02/04/2022 | 01/04/2022 | Completed |
| Occurance | 100% visual inspection started before dispatch to plating (outsource) | Nice Team | 01/04/2022 | 01/04/2022 | Completed |
| Outflow | Training provided to inspector for both similar part | Nice Team | 02/04/2022 | 01/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection started before dispatch to plating (outsource) |
| Inspection Method | Other |
| Other Inspection Method | Visual inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Only sapling inspection being done 13_Occurance_Before.pdf |
| Occurance (After) |
Training provided to all concern person about visual inspection . 13_Occurance_After.pdf |
| Outflow (Before) |
No any OPL 13_Outflow_Before.pdf |
| Outflow (After) |
OPL made and displayed 13_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | No |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | Inspection added |
13. Effectiveness Of Action
| Reviewed Quantity | 10000 |
| Reason for submission | reviewed 10000 no mix up issue |