QFR No - 8000785257
Defect Details
| NC No. | 8000785257 |
| NC Date | 25/04/2022 |
| NC Submission Date | |
| Part No. | S2HS21103B |
| Part Name | OUTER TUBE PLATED K3 NEW |
| Supplier Name & Code | 101273-SAPTAGIRI ENGINEERING PRIVATE |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | PLATING NOT OK-PLATING PEEL OFF |
1. Problem Description
| Defect Description | Outer Tube K3 Model Plating peel off issue |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 177 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | nda0pbc12ahfych2ukeoeucg.png |
Supplier Communication Details
| Quality Head Email ID | quality@saptagirigroup.in |
| Plant Head/CEO Email ID | production@saptagirigroup.in |
| MD Email ID |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
5000
|
0
|
0
|
2545
|
0
|
7545
|
| Check Qty |
5000
|
0
|
0
|
2545
|
0
|
7545
|
| NG Qty |
1089
|
0
|
0
|
3
|
0
|
1092
|
| Scrap | 3 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| We have checked available stock at ETL end |
3. Process Flow
| Process Flow Description |
|---|
| Raw Material Inward (CEW Tube),Tube Cutting & O.D. Chamfering, Both side I.D. Chamfering ,Forming,CNC Machining,Marking,Buffing,Plating,100% Thread Inspection |
4. Process Details
| Process / Operation | Plating |
| Outsource | No |
| Machine / Cell | Plating |
| Machine / Cell No. | Line-1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Maintain pH of water rinse bath before nickel plating | Low pH of water rinse bath before nickel plating | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Bend test |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 4 |
7. Root Cause Analysis (Occurance)
| Why 1 | peel off in outer tube |
| Why 2 | Outer tube passivate in water rinse after acid dip |
| Why 3 | Low pH of water rinse bath before nickel plating |
| Why 4 | Carryover of acid dip solution to next water rinse |
| Why 5 | Higher concentration of acid dip bath resulted into higher concentrated solution of next bath (i.e. water rinse |
| Root Cause (Occurance) | Component get passivate due to dipped in High concentrated water rinse bath which is after acid dip. |
Root Cause Analysis (Outflow)
| Why 1 | peel off in outer tube |
| Why 2 | Bend test checking sampling plan less |
| Why 3 | During bend test not detect |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | During bend test not detect |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | One sample was tested for bend test now we have started 4 nos sample bend test per day. | QA | 20/04/2022 | 20/04/2022 | Completed |
| Occurance | Weekly PM of water rinse bath (Stage no. 17) changed to thrice in a week (i.e. on second day of running condition) | QA / Production | 19/04/2022 | 20/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% file test monitoring to be done for plated Outer Tube. |
| Inspection Method | Other |
| Other Inspection Method | Sampling increase |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 4 per day |
10. Evidance of Countermeasure
| Occurance (Before) |
Weekly PM of water rinse bath (Stage no. 17) 66_Occurance_Before.pptx |
| Occurance (After) |
PM of water rinse bath (Stage no. 17) changed to thrice in a week (i.e. on second day of running condition) 66_Occurance_After.pdf |
| Outflow (Before) |
One sample was tested for bend test 66_Outflow_Before.pdf |
| Outflow (After) |
now we have started 4 nos sample bend test per day. 66_Outflow_After.pptx |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Plated outer tube |
12. Document Review
| Documents | ControlPlan, PMCheckSheet, WISOP |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 2000 |
| Reason for submission | Plating peel off on Outer Tube |