QFR No - 8000785994
Defect Details
| NC No. | 8000785994 |
| NC Date | 05/05/2022 |
| NC Submission Date | |
| Part No. | 520GA00202 |
| Part Name | MODIFIED DUST SEAL 30DIA HTA |
| Supplier Name & Code | 100109-HI TECH ARAI PVT LIMITED |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | FITTMENT NOT OK.-INSERT MATERIAL NOT AVAILABLE |
1. Problem Description
| Defect Description | Dust seal with out insert material |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | balamurugan.sb@hitecharai.com |
| Plant Head/CEO Email ID | sukumar@hitecharai.com |
| MD Email ID | spm32@hotmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
0
|
0
|
0
|
6400
|
0
|
6400
|
| Check Qty |
0
|
0
|
0
|
6399
|
0
|
6399
|
| NG Qty |
0
|
0
|
0
|
1
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| The Parts are additionally checked before dispatch |
3. Process Flow
| Process Flow Description |
|---|
| Moulding--> Deflashing-->Trimming--> Air Cleaning-->100% VI-->Air Cleaning-->Audit Inspection-->Packing-->Dispatch |
4. Process Details
| Process / Operation | Moulding |
| Outsource | No |
| Machine / Cell | NA |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | The Visual Inspection Skipped | The Operator skipped the part without press and check | O |
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 | The metal insert was missed to load in the cavity during moulding. |
| Why 2 | Manual loading of shells in the cavity during moulding. |
| Why 3 | Molding operator not noticed the shell missing in cavity before mold closing. |
| Why 4 | The metal insert after Loading to the cavity not visible. |
| Why 5 | |
| Root Cause (Occurance) | The Verification of Metal Insert after Loading to cavity is not Viable. |
Root Cause Analysis (Outflow)
| Why 1 | Seal without metal insert not detected before dispatch. |
| Why 2 | Need additional detection control to ensure metal insert moulded with seal. |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Need additional detection control to ensure metal insert moulded with seal. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Molding operator provided additional training. | HTA | 22/04/2022 | 22/04/2022 | Completed |
| Outflow | Metal Insert(Shell) Poka Yoke system introduced in Trimming process. | HTA | 22/04/2022 | 22/04/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NA |
| Inspection Method | Other |
| Other Inspection Method | NA |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | n=5 |
10. Evidance of Countermeasure
| Occurance (Before) |
The Verification of Metal Insert after Loading to cavity is not Viable. 87_Occurance_Before.pdf |
| Occurance (After) |
Molding operator provided additional training. 87_Occurance_After.pdf |
| Outflow (Before) |
In Trimming Process earlier there is no metal checking sensor available 87_Outflow_Before.pdf |
| Outflow (After) |
Metal Checking sensor implemented in the trimming process to avoid outflow of without metal insert part. 87_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Part No. 520GA00202 |
12. Document Review
| Documents | PokayokeCheckSheet |
| Specify Other Document | Training Record |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |