QFR No - 8000782421
Defect Details
| NC No. | 8000782421 |
| NC Date | 31/03/2022 |
| NC Submission Date | |
| Part No. | 520PC03307 |
| Part Name | UNDER BKT SUB-ASSY. K3 |
| Supplier Name & Code | 100348-SINGLA FORGING |
| ETL Plant | 1126-ETL Pantnagar |
| Defect Details | POWDER COATING NOT OK-POWDER COATING UNCOVER |
1. Problem Description
| Defect Description | Powder coating uncover in Under bracket at BAL |
| Detection Stage | Customer End |
| Problem Severity | Aesthetic |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | pntquality@singlaforging.in |
| Plant Head/CEO Email ID | deepakgupta@singlaforging.com |
| MD Email ID | jain@singlaforging.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
150
|
0
|
0
|
180
|
0
|
330
|
| Check Qty |
150
|
0
|
0
|
180
|
0
|
330
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 0 |
| Rework | 1 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 1-100% segregation of material lying at various stages to be done with OK confirmation marking 2-Quality Alert to be displayed at work station |
3. Process Flow
| Process Flow Description |
|---|
| Operation No Operation 10 Receipt of Material 20 Receipt Inspection 30 Storage 40 VMC Machining-I 50 VMC Machining-II 60 VMC Machining-III 70 Slitting 80 Received material & Inspection 90 Pipe Pressing, 100 Welding 110 Powder Coating 120 Final Inspection 130 Packing 140 Dispatch |
4. Process Details
| Process / Operation | Powder Coating |
| Outsource | Yes |
| Machine / Cell | Powder Coating cell |
| Machine / Cell No. | Unmasking |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Method of unmasking not adequate | Checked and obserbed method of unmasking was not adeqate.i.e operator was unmasking the side id mask | X |
| Method | Method of applying powder through gun not adequate | Checked and verfied that trained operator are applying powder through gun in booth | O |
| Method | Insp method not adequate | Checked & verifed that inspector was doing the visual inspection | O |
| Man | Unskilled/Unaware Inspector/operator | Checked & verified that skilled inspector/operator are working but having some unawareness | X |
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 | Method of unmasking of side ID of powder coated parts was not adequate. |
| Why 2 | Operator was removing the masking from the side ID directly with hand before moving of powder coated parts in the oven.. |
| Why 3 | No other provisions for removing the masking from the powder coated part not available. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | No other provisions for removing the masking from the powder coated part not available. |
Root Cause Analysis (Outflow)
| Why 1 | Powered coated uncover part skipped from the final stage |
| Why 2 | Part was not detected in the final inspection stage. |
| Why 3 | Inspector was not aware. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspector was not aware. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 1-Method of removing the masking will be defined i.e. masking will be removed through plastic stick. | Mukesh Kumar Singh | 06/04/2022 | 04/04/2022 | Completed |
| Occurance | 2-WI for removing of masking to be made & displayed. | Mukesh Kumar Singh | 06/04/2022 | 04/04/2022 | Completed |
| Outflow | 1-Awareness training to be provided to the final inspector. | Sarvesh Kumar | 06/04/2022 | 05/04/2022 | Completed |
| Outflow | 100% visual inspection is started at M/s steel Engineers end with proper identification marking. | Mukesh Kumar Singh | 06/04/2022 | 02/04/2022 | Completed |
| Outflow | Powder coating defects matrix to be made & displayed at final inspection stage and training to be provided | Sunil | 04/04/2022 | 04/04/2022 | Completed |
| Occurance | 3-OJT to be provided for removing the masking. | Mukesh Kumar Singh | 06/04/2022 | 05/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% visual inspection is started at M/s steel Engineers end with proper identification marking. |
| 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) |
Masking pull directly from the part before oven through hand 35_Occurance_Before.xlsx |
| Occurance (After) |
Method of removing the masking will be defined i.e masking will be removed through plastic stick. 35_Occurance_After.pdf |
| Outflow (Before) |
Not Available 35_Outflow_Before.pdf |
| Outflow (After) |
Powder coating defects matrix to be made & displayed at final inspection stage and training to be provided. 35_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | ALL UBA |
12. Document Review
| Documents | WISOP |
| Specify Other Document | no |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | OK |