QFR No - 8000788019
Defect Details
| NC No. | 8000788019 |
| 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 | SHADE VARIATION-SHADE VARIATION |
1. Problem Description
| Defect Description | Shade Variation i.e. Heavy Blueness observed |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 200 |
| 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
|
500
|
1000
|
1000
|
1000
|
3500
|
| Check Qty |
0
|
500
|
1000
|
1000
|
1000
|
3500
|
| NG Qty |
0
|
0
|
0
|
500
|
0
|
500
|
| Scrap | 0 |
| Rework | 500 |
| Under Deviation | 0 |
| Containment Action |
|---|
| RE-PLATING DONE IN ALL SUSPECTED MATERIAL |
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 | PLATING |
| Outsource | Yes |
| Machine / Cell | PASSIVATION TANK |
| Machine / Cell No. | PASSIVATION TANK |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | WRONG MATERIAL USED | MATERIAL OK AS PER DRAWING | O |
| Tool | TOOL WEAR OUT | TOOL FOUND OK | O |
| Method | PASSIVATION TIME WAS LESS | PROCESS CHECKSHEET | X |
| Man | UNTRAINED OPERATOR | SKILL MATRIX AVAILABLE | O |
| Machine | MACHINE CAPACITY NOT OK | CAPACITY OK AS PER DEFINED | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | CHEMICAL ANALYSIS |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | AS PER |
7. Root Cause Analysis (Occurance)
| Why 1 | PASSIVATION COLOUR CHANGED |
| Why 2 | PASSIVATION NOT DONE AS PER REQUIERMENT |
| Why 3 | PASSIVATION TIME WAS LESS |
| Why 4 | LOT REMOVED FROM TANK BEFORE REQUIERD TIME |
| Why 5 | MANUAL CONTROL |
| Root Cause (Occurance) | PASSIVATION TIME WAS LESS |
Root Cause Analysis (Outflow)
| Why 1 | WRONG PASSIVATION PARTS DISPATCHED |
| Why 2 | BOTH PASSIVATION PARTS PASSED BY FINALMINSPECTOR |
| Why 3 | LIMIT SAMPLES WAS NOT DEFINED |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | MASTER SAMPLE WAS NOT AVAILABLE |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | PLC LINE IMPLEMENTED FOR ALL PARAMETER CONTROLLING LIKE TIME , TEMP ETC | NICE | 24/05/2022 | 15/05/2022 | Completed |
| Outflow | SAMPLE PROVIDED TO FINAL INSPECTION TEAM FOR COLOUR VARATION | NICE | 22/05/2022 | 15/05/2022 | Completed |
| Occurance | PASSIVATION TIME FROZEN | NICE STEEL IND | 01/11/2022 | 15/05/2022 | Inprocess |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% VIUSAL INSPECTION STARTED |
| Inspection Method | Other |
| Other Inspection Method | VISUAL WITH SAMPLE |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | OPL |
10. Evidance of Countermeasure
| Occurance (Before) |
BEFORE - PROCESS/LINE PICTURE ATTACHED 140_Occurance_Before.jpg |
| Occurance (After) |
AFTER-PROCESS/LINE PICTURE ATTACHED 140_Occurance_After.jpg |
| Outflow (Before) |
BEFORE - CP FILE ATTACHED 140_Outflow_Before.pdf |
| Outflow (After) |
AFTER-CP FILE ATTACHED 140_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NO APPLICABLE |
12. Document Review
| Documents | ControlPlan |
| Specify Other Document | NOT REQUIRED |
13. Effectiveness Of Action
| Reviewed Quantity | 0 |
| Reason for submission | Problem Analysis Fact Verification observation to be written in details. Also Occurence side why why analysis side caus and action are not adequate. Flow side Countermeasuers are not taken and Documents reviewed and updated are not adequate. |