QFR No - 8000782143
Defect Details
| NC No. | 8000782143 |
| NC Date | 28/03/2022 |
| NC Submission Date | |
| Part No. | 580DV00102 |
| Part Name | GEAR CONTROL PULLY H BAR ASSLY(24191184) |
| Supplier Name & Code | 101086-PUNE POLYMERS PVT. LTD. |
| ETL Plant | 1102-ETL L-6 Die Casting |
| Defect Details | FITTMENT NOT OK.-HOLE SHIFT |
1. Problem Description
| Defect Description | Diameter 2.2 Shift |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 669 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qa.waluj@punepolymers.com |
| Plant Head/CEO Email ID | planthead.waluj@punepolymers.com |
| MD Email ID | s.gupta@punepolymers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5000
|
0
|
0
|
1500
|
1500
|
8000
|
| Check Qty |
5000
|
0
|
0
|
1500
|
1500
|
8000
|
| NG Qty |
550
|
0
|
0
|
0
|
0
|
550
|
| Scrap | 550 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % inspection done for all material in stock. |
3. Process Flow
| Process Flow Description |
|---|
| In. molding - Inspection - packing - Dispatch |
4. Process Details
| Process / Operation | Inj. molding |
| Outsource | No |
| Machine / Cell | Cell A |
| Machine / Cell No. | Cell A |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | Pin bent in mold. | Pin bent in mold. | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10 |
7. Root Cause Analysis (Occurance)
| Why 1 | Fitment not ok |
| Why 2 | Hole shift |
| Why 3 | Pin bent in mold. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Pin bent in mold. |
Root Cause Analysis (Outflow)
| Why 1 | Skipped from inspection. |
| Why 2 | Not detected in sampling. |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Not detected in sampling. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Pin replaced in the mold. | PPPL | 15/04/2022 | 15/04/2022 | Completed |
| Outflow | 100 % inspection | PPPL | 05/04/2022 | 05/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % inspection. |
| 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) |
Pin bent 30_Occurance_Before.xls |
| Occurance (After) |
Pin replaced. 30_Occurance_After.xls |
| Outflow (Before) |
Sampling inspection. 30_Outflow_Before.xls |
| Outflow (After) |
100 % inspection. 30_Outflow_After.xls |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP, InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 50000 |
| Reason for submission | Monitor for next one month & no issue observed |