QFR No - 8000786395
Defect Details
| NC No. | 8000786395 |
| NC Date | 05/05/2022 |
| NC Submission Date | |
| Part No. | S1AB00612B |
| Part Name | ADJUSTER PLATED |
| Supplier Name & Code | 100782-NICE STEEL INDUSTRIES |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | BUFFING DEFECT-BUFFING STEP, PLATING DEFECTS, |
1. Problem Description
| Defect Description | Buffing Defects like Buffing Step, Buff Cut mark, Heavy Buffing Lines |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 105 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | ppc.nice@batragroup.biz |
| Plant Head/CEO Email ID | ho.nice@batragroup.biz |
| MD Email ID | hitesh@batragroup.biz |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1000
|
1000
|
1000
|
1000
|
1000
|
5000
|
| Check Qty |
1000
|
1000
|
1000
|
1000
|
1000
|
5000
|
| NG Qty |
0
|
1
|
1
|
1
|
0
|
3
|
| Scrap | 0 |
| Rework | 1 |
| Under Deviation | 0 |
| Containment Action |
|---|
| ALL MATERIAL SEGREGATED BT NICE STEEL IND. |
3. Process Flow
| Process Flow Description |
|---|
| 10- BLANK 20- U BENDING 30- ROUNDING 40- WELDING 50- FLAIRING 60- ID SIZING 70 -SIDE(OD) GRINDING 80-BROACHING 90-HEAD GRINDING 100- PLATING(OUT SOURCE) 110-RECEIPT FROM PLATING 120-FINAL INSPECTION 130- PACKING & DISPATCH |
4. Process Details
| Process / Operation | 70 -SIDE(OD) GRINDING |
| Outsource | No |
| Machine / Cell | 70 -SIDE(OD) GRINDING |
| Machine / Cell No. | GRINDING |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | WRONG MATERIAL USED | MATERIAL VERIFIED AND FOUND OK | O |
| Machine | MACHINE UNDER OR OVER CAPACITY | MACHIN CAPACITY WAS OK | O |
| Man | UNTRAINED OPERATOR | OPREATOR WAS SKILLED | O |
| Method | UTTING FORCE WAS UNEVEN | WELDING BEAD NOT REMOVED IN UNIFORM SHAPE | X |
| Tool | WRONG BELT USED | BELT FOUND OK | O |
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 | STEP OBSERVED ON FACE OUTER DIA |
| Why 2 | WELDING BEAD WAS NOT GRIND IN UNIFORM SHAPE |
| Why 3 | WELDING BEAD NOT REMOVED PROPERLY |
| Why 4 | CUTTING FORCE WAS NOT IN PROPER WAY |
| Why 5 | OPERATOR NEGLIGENCE |
| Root Cause (Occurance) | WELDING BEAD WAS NOT GRIND IN UNIFORM SHAPE |
Root Cause Analysis (Outflow)
| Why 1 | STEP OBSERVED IN PARTS AT CUTOMER END |
| Why 2 | PROBLEM COULD NOT FOUND DURING INSPECTION |
| Why 3 | THIS PROBLEM WAS OBSERVED FIRST TIME |
| Why 4 | SAMPLE WAS NOT AVAILABLE |
| Why 5 | |
| Root Cause (Outflow) | THIS PROBLEM WAS OBSERVED FIRST TIME |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | TRAINING PROVIDED TO OPREATOR FOR OD BUFFING | NICE STEEL IND | 10/05/2022 | 21/07/2022 | Completed |
| Outflow | SAMPLE PROVIDED FOT VISUAL INSPECTION | NICE STEEL IND. | 10/05/2022 | 21/07/2022 | Completed |
| Outflow | TRAINING PROVIDED TO ALL CONCERN PERSON | NICE STEEL IND | 10/05/2022 | 21/07/2022 | Completed |
| Occurance | OPL DISPLAYED AT SHOP FLOOR FOR AWARENESS | NICE STEEL IND | 10/05/2022 | 21/07/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% visual inspection started |
| Inspection Method | Other |
| Other Inspection Method | INSPECTOR DEFINED |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
NA 86_Occurance_Before.jpg |
| Occurance (After) |
1-TRAINING PROVIDED TO ALL CONCERN PERSON 2- OPL DISPLAYED 3- SAMPLE PROVIDED 86_Occurance_After.pdf |
| Outflow (Before) |
NA 86_Outflow_Before.jpg |
| Outflow (After) |
1-TRAINING PROVIDED TO ALL CONCERN PERSON 2- OPL DISPLAYED 3- SAMPLE PROVIDED 86_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | ALL ADJUSTER |
12. Document Review
| Documents | WISOP |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 7500 |
| Reason for submission | Found Ok in Reviewed Qty. |