QFR No - 8000782061
Defect Details
| NC No. | 8000782061 |
| NC Date | 27/03/2022 |
| NC Submission Date | |
| Part No. | 520CJ00102 |
| Part Name | COPPER WASHER |
| Supplier Name & Code | 100152-GOLDY PRECISION STAMPINGS PVT. |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | EXCESS CUT/SANDERING-CUT FROM EDGE |
1. Problem Description
| Defect Description | Part Cut From OD |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 5 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | rfo2mvbruc002pra10ggh2kq.png |
Supplier Communication Details
| Quality Head Email ID | quality@goldy.in |
| Plant Head/CEO Email ID | mangesh.chaudhary@goldy.in |
| MD Email ID | sidhesh.raikar@goldy.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
10000
|
0
|
0
|
10000
|
0
|
20000
|
| Check Qty |
10000
|
0
|
0
|
10000
|
0
|
20000
|
| NG Qty |
5
|
0
|
0
|
0
|
0
|
5
|
| Scrap | 5 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Finish good qty 10000 Nos verify at visual inspection found ok. |
3. Process Flow
| Process Flow Description |
|---|
| 10- RAW MATERIAL INSPECTION, 20-BLANKING, 30-ANNELING, 40-100% VISUAL INSPECTION, PACKING & FG STOCK, 50-FINAL INSPECTION & DISPATCH |
4. Process Details
| Process / Operation | BLANKING |
| Outsource | No |
| Machine / Cell | PRESS MACHINE |
| Machine / Cell No. | P-4 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Operator skill | Verify opeartor skill as per Enducation & training, operator found trained | O |
| Method | Blanking method not ok | Checked method as per work instruction found ok | O |
| Tool | Tool not ok | Verify Tool condition, dowel pin found not ok | X |
| Machine | Machine not ok | Checked Parameter checked founf ok | O |
| Material | Material not ok | Material thickness width, hardness checked found ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | VISUAL |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Outer Diameter cut found parts no- 520CJ00102 |
| Why 2 | Outer diameter cut during blanking while strip feeding |
| Why 3 | Strip Overlap feed because toll dowel not control to overlap operation |
| Why 4 | Dowel pin not ok, dowel pin height in sufficient |
| Why 5 | NOT APPLICABLE |
| Root Cause (Occurance) | Dowel pin not ok, dowel pin height in sufficient |
Root Cause Analysis (Outflow)
| Why 1 | Outer diameter cut parts skipped in visual inspection |
| Why 2 | Operator could not detect to cut parts |
| Why 3 | Operator take more parts on table for visual inspection |
| Why 4 | NOT APPLICABLE |
| Why 5 | NOT APPLICABLE |
| Root Cause (Outflow) | Operator take more parts on table for visual inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1) Dowel pin height increase more than 2 mm of thickness. (Height increase 3.5 against 1.5mm) 2) Operator verify pin height condition before start blanking. | Vikas Divate / Rahul kandale | 28/03/2022 | 28/03/2022 | Completed |
| Outflow | 10-12 no`s parts checking started on visual inspection on table | Rahul Pawar | 29/03/2022 | 29/03/2022 | Completed |
| Outflow | Training given to visual inspector for part inspection | Rahul Pawar / Vikas Divate | 29/03/2022 | 29/03/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 10-12 no`s parts checking started on visual inspection on table |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Dowel pin not ok, dowel pin height in sufficient 27_Occurance_Before.pdf |
| Occurance (After) |
1) Dowel pin height increase more than 2 mm of thickness. (Height increase 3.5 against 1.5mm) 2)Operator verify pin condition before start blanking. 27_Occurance_After.pdf |
| Outflow (Before) |
Operator take more parts on table for visual inspection 27_Outflow_Before.pdf |
| Outflow (After) |
10-12 no`s parts checking started on visual inspection on table 27_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Cooper parts - 520CJ00502 & 520CJ00702 |
12. Document Review
| Documents | ControlPlan, PFMEA |
| Specify Other Document | Before after |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Accepted |