QFR No - 8000783854
Defect Details
| NC No. | 8000783854 |
| NC Date | 14/04/2022 |
| NC Submission Date | |
| Part No. | F2AV00902B |
| Part Name | BELLOW -ABWB |
| Supplier Name & Code | 101023-FORES ELASTOMECH INDIA PVT. LT |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-DAMAGED PARTS TORN BELLOW |
1. Problem Description
| Defect Description | DIRT DAMAGES ON PLATE |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 82 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | malani.pritam@foresgroup.com |
| Plant Head/CEO Email ID | singh.barinder@foresgroup.com |
| MD Email ID | swamy.pj@foresgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
0
|
0
|
1000
|
0
|
2000
|
| Check Qty |
1000
|
0
|
0
|
1000
|
0
|
2000
|
| NG Qty |
2
|
0
|
0
|
0
|
0
|
2
|
| Scrap | 2 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% stock verification at ETL end |
3. Process Flow
| Process Flow Description |
|---|
| Rubber & Chemical >Incoming inspection > Mixing rubber compound > Moulding > Visual Inspection > Packing & Dispatch . |
4. Process Details
| Process / Operation | Rubber Moulding |
| Outsource | No |
| Machine / Cell | Moulding |
| Machine / Cell No. | Moulding |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Skip for inspection | Inspector not quarantine NG parts | O |
| Machine | Mould temperature not okay | PLC controlled process parameter machine | 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 | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Flow mark on part |
| Why 2 | Material Flow not uniform |
| Why 3 | Dirt deposition in cavity |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Dirt deposition in cavity |
Root Cause Analysis (Outflow)
| Why 1 | Material flow mark on part |
| Why 2 | Skip from inspection |
| Why 3 | Not okay material mix up in okay part |
| Why 4 | inspector not quarantine NG parts |
| Why 5 | |
| Root Cause (Outflow) | Inspector not aware about the issue |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Dirt polishing frequency is increase | Fores | 19/04/2022 | 19/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No change |
| 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) |
Dirt polishing frequency is less i.e After 15days of production 51_Occurance_Before.png |
| Occurance (After) |
1.Dirt polishing frequency is increase i.e After 7 days of production .
2.OPL display at production stage . 51_Occurance_After.png |
| Outflow (Before) |
Inspector not aware about the issue 51_Outflow_Before.pdf |
| Outflow (After) |
1.Training given to inspector .
2. OPL display at inspection stage . 51_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | N/A |
12. Document Review
| Documents | |
| Specify Other Document | N/A |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | Occurrence side & outflow side before after evidences are same. Also Horizontal deployment of action can be taken in FAV00302 which is not considered.(Same defect is repeating in F2AV00302) |