QFR No - 8000782619
Defect Details
| NC No. | 8000782619 |
| NC Date | 03/04/2022 |
| NC Submission Date | |
| Part No. | S2HT52107B |
| Part Name | OUTER SPRING K0PG |
| Supplier Name & Code | 101225-HELICAL SPRINGS |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | NOT AS PER SPECIFICATION-PAINT FAULT I.E. PAINT BURN OBSERVED |
1. Problem Description
| Defect Description | Paint Fault |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 1 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | wqqohlt4d2sjrzmz0ygurfve.jpg |
Supplier Communication Details
| Quality Head Email ID | arun@helicalsprings.in |
| Plant Head/CEO Email ID | shaikhmoin@helicalsprings.in |
| MD Email ID | ataneja@helicalsprings.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2016
|
4000
|
0
|
0
|
0
|
6016
|
| Check Qty |
2016
|
4000
|
0
|
0
|
0
|
6016
|
| NG Qty |
1
|
0
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% inspection done at ETL & Warehouse. |
3. Process Flow
| Process Flow Description |
|---|
| RM, COILING, Stress Releiving-1, Grinding, Shotpeening, Scragging, ID, Length & E1,E2 Checking , Stress Relieving-2, Surface Finish-Powder Coating (Out Source) KRISHNA COATING, Final Inspection. |
4. Process Details
| Process / Operation | Powder Coating |
| Outsource | Yes |
| Machine / Cell | NA |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | unskilled Operator | Skill matrix checked found ok | O |
| Method | Hook profile change | Profile changed hooks not replaced | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 5 Nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Paint burn (Touch Mark) |
| Why 2 | Powder removed from spring surface |
| Why 3 | Due to spring touching to other spring during coating |
| Why 4 | Profile change hooks not replaced in few hangers |
| Why 5 | |
| Root Cause (Occurance) | Profile change hooks not replaced in few hangers |
Root Cause Analysis (Outflow)
| Why 1 | Paint burn (Touch Mark) |
| Why 2 | Online inspection done. |
| Why 3 | PDIR done before dispatch but not detected in sampling. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Online inspection done. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Two Stage inspection Start I. Online Inspection II. Inspection on table | Krishna Coating | 07/04/2022 | 06/04/2022 | Completed |
| Occurance | Monitoring hook condition at loading stage | Krishna Coating | 07/04/2022 | 06/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 2 Stage inspection Start I. Online Inspection II. Inspection on table |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 5 Nos |
10. Evidance of Countermeasure
| Occurance (Before) |
Profile change hooks not replaced in few hangers 43_Occurance_Before.pdf |
| Occurance (After) |
Monitoring hook condition at loading stage for avoiding touching during coating 43_Occurance_After.pdf |
| Outflow (Before) |
Online Inspection. 43_Outflow_Before.pdf |
| Outflow (After) |
Stage inspection Start I. Online Inspection II. Inspection on table 43_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Powder Coated Part. |
12. Document Review
| Documents | |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 0 |
| Reason for submission | To avoid hook (Spring) distance to be proper what action has been taken??? Training record for operator. Document i.e. Hanger PM and hook inspection sheet on daily bases not attached. 1st and 2nd stage inspection can have two different color making to make sure inspection is performed 100% twice at 2 stages. |