QFR No - 8000788017
Defect Details
| NC No. | 8000788017 |
| NC Date | 19/05/2022 |
| 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 | WELDING NOT OK-WELDING BLOW HOLE AT OD SURFACE |
1. Problem Description
| Defect Description | Blow Hole at OD Surface (Above the welding area) |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 1 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | pebw2vym4iu2pqxmtsmh5bjd.png |
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 |
0
|
1000
|
0
|
2000
|
2000
|
5000
|
| Check Qty |
0
|
1000
|
0
|
2000
|
2000
|
5000
|
| NG Qty |
0
|
0
|
0
|
0
|
5
|
5
|
| Scrap | 5 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| ALL MATERIAL SEGREGATED |
3. Process Flow
| Process Flow Description |
|---|
| 10- RECEIVING INSPECTION 20- STORAGE 30-BLANK 40- U-BENDING 50-ROUNDING 60-WELDING 70- FLARING 80- ID SIZING 90-SIDE GRINDING 100-BROACHING 110-HEAD GRINDING & BUFFING 120- OUT SIDE MOVEMENT FOR PLATING 130-STORAGE & RQC OF PLATED MATERIAL 140-FINAL INSPECTION 150-PACKING & DISPATCH |
4. Process Details
| Process / Operation | WELDING |
| Outsource | No |
| Machine / Cell | WELDING MACHINE |
| Machine / Cell No. | MC NO-1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | TOOL WORN OUT | TOOL OK | O |
| Method | NOZZEL WAS NOT CLEAN | GASS FLOW IMPROPER | X |
| Man | UNTRAINED OPREATOR | SKILL MATRIX | O |
| Machine | UNDER/OVER CAPACITY MACHINE USED | FOUND CAPACITY WAS OK | O |
| Material | WRONG MATERIAL/GRADE USED | MATERIAL FOUND OK | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | VISUAL |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | VISUAL |
7. Root Cause Analysis (Occurance)
| Why 1 | WELDING NOT DONE IN PART |
| Why 2 | WELDING UNFILL |
| Why 3 | PIN HOLES ON TO AREA |
| Why 4 | GAS NOT PROPERLY FLOW |
| Why 5 | NOZZEL CLEANING FRQUENCY WAS NOT DEFINED |
| Root Cause (Occurance) | NOZZEL CLEANING FRQUENCY WAS NOT DEFINED |
Root Cause Analysis (Outflow)
| Why 1 | DEFECTIVE PARTS COULD NOT DETECT DURING FINAL INSPECTION |
| Why 2 | INSPECTOR WAS NOT AWAR ABOUT THE DEFECT |
| Why 3 | PROBLEM FOUND FIRST TIME |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | INSPECTOR WAS NOT AWAR ABOUT THE DEFECT |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | NOZZEL CLEANING FRQUENCY TO DEFINED | NICE STEEL IND | 01/06/2022 | 01/06/2022 | Completed |
| Outflow | LIMIT SAMPLES TO BE PROVIDED FOT OK AND NG | NICE STEEL IND | 01/06/2022 | 01/06/2022 | Completed |
| Outflow | ONE POINT LESSON UPDATED | NICE STEEL IND | 01/06/2022 | 01/06/2022 | Completed |
| Outflow | TRAINING PROVIDED TO ALL CONCERN PERSON | NICE STEEL IND | 01/06/2022 | 01/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% VISUAL INSPECTION STARTED |
| Inspection Method | Other |
| Other Inspection Method | VISUAL |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | VISUAL |
10. Evidance of Countermeasure
| Occurance (Before) |
NA 138_Occurance_Before.jpg |
| Occurance (After) |
NOZZALE CLEANING FRQUENCY DEFINED 138_Occurance_After.pdf |
| Outflow (Before) |
NA 138_Outflow_Before.jpg |
| Outflow (After) |
1-TRAINING PROVIDED TO ALL 2- OPL DISPLAYED 138_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NO |
12. Document Review
| Documents | ControlPlan, WISOP |
| Specify Other Document | NO |
13. Effectiveness Of Action
| Reviewed Quantity | 6000 |
| Reason for submission | Verified qty of 6000 Nos by 100% inspection and found effective. |