QFR No - 8000788018
Defect Details
| NC No. | 8000788018 |
| 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 SPATTER |
1. Problem Description
| Defect Description | Welding Spatter at Outer Surface |
| 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
|
1000
|
4000
|
| Check Qty |
0
|
1000
|
0
|
2000
|
1000
|
4000
|
| NG Qty |
0
|
1
|
0
|
0
|
0
|
1
|
| Scrap | 1 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| ALL MATERIAL TO BE RECHECKED |
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 / Cell No. | 1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | WRONG MATERIAL USED | MTC VERIFIED AND FOUND OK | O |
| Man | UNTRAINED OPERATOR | SKILL MATRIX AVAILABLE | O |
| Machine | LOW/HIGHER CAPACITY MACHINE USED | MACHINE FOUND OK | O |
| Tool | TIP/NOZZELE WAS NOT CLEAN | NOZZEL CLEANING NOT DONE | X |
| Method | PROCESS SHEET WAS NOT FOLLOWED | CHECK AND 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 | WELDING SPATTER IN PART |
| Why 2 | WELDING PARTICALS GENERATED DURING WELDING |
| Why 3 | WELDING WIRE STUCK IN NOZZELE |
| Why 4 | WELDING DUST IN NOZZELE |
| Why 5 | NOZZELE WAS NOT CLEAN |
| Root Cause (Occurance) | 1-WELDING DUST IN NOZZELE 2-NOZZELE WAS NOT CLEAN |
Root Cause Analysis (Outflow)
| Why 1 | DEFECTIVE PART NOT DETECT DURING INSPECTION |
| Why 2 | PROBLEM COULD NOT DETECT DURING SAMPLING INSPECTION |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | PROBLEM COULD NOT DETECT DURING SAMPLING INSPECTION |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | NOZZELE CLEAING FREQUENCY TO BE DEFINED | NICE STEEL | 01/09/2022 | 14/06/2022 | Completed |
| Outflow | OPL DISPLAYED AND 100% VISUAL INSEPCTION STARTED | NICE | 01/09/2022 | 14/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% VISUAL INSPECTION |
| 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) |
MACHINE CHECKSHEET ATTACHED 139_Occurance_Before.pdf |
| Occurance (After) |
MACHINE CHECKSHEET ATTACHED 139_Occurance_After.pptx |
| Outflow (Before) |
NO ANY DOCUMENTS 139_Outflow_Before.pdf |
| Outflow (After) |
OPL ATTACHED 139_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | .... |
12. Document Review
| Documents | PMCheckSheet, WISOP, JHCheckSheet |
| Specify Other Document | TRAINING RECORDS |
13. Effectiveness Of Action
| Reviewed Quantity | 10500 |
| Reason for submission | Reviewed quantity and found not repeated |