QFR No - 8000788189
Defect Details
| NC No. | 8000788189 |
| NC Date | 20/05/2022 |
| NC Submission Date | |
| Part No. | 550GA01502 |
| Part Name | DUST SEAL Ø41_SFN |
| Supplier Name & Code | 101055-FREUDENBERG-NOK PRIVATE LIMITE |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-DEFORMED PARTS |
1. Problem Description
| Defect Description | DUST SEAL TOP AREA DEFORMED |
| Detection Stage | Inprocess |
| Problem Severity | Function |
| NG Quantity | 3 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | jq1zd3jwbvlx5fndf34ouof2.pptx |
Supplier Communication Details
| Quality Head Email ID | manpreet.rahi@fst.com |
| Plant Head/CEO Email ID | Vishal.Inge@fst.com |
| MD Email ID | anand.thiagarajan@fst.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
35000
|
45000
|
0
|
60000
|
0
|
140000
|
| Check Qty |
35000
|
45000
|
0
|
60000
|
0
|
140000
|
| NG Qty |
6
|
4
|
0
|
0
|
0
|
10
|
| Scrap | 6 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% reverification of parts for seal deformation |
3. Process Flow
| Process Flow Description |
|---|
| Moulding - Trimming- Visual Inspection - Packing |
4. Process Details
| Process / Operation | Moulding |
| Outsource | No |
| Machine / Cell | Moulding Machine |
| Machine / Cell No. | Compression Moulding |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Low Curing Time | PLC Controlled | X |
| Machine | Mould opening delay time | Yes | O |
| Machine | Less Mould Temperature | PLC Controlled | X |
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 | Curing observed in dust seal at lip area |
| Why 2 | Mould temperature reduces in mould @ corner cavity |
| Why 3 | Possibility observed of mould opening time delay after moulding process |
| Why 4 | Inadequate controlling mechanism for mould delay time in moulding process |
| Why 5 | |
| Root Cause (Occurance) | Inadequate controlling mechanism for mould delay time in moulding process |
Root Cause Analysis (Outflow)
| Why 1 | Curing in dust seal lip area not detected @FNI |
| Why 2 | Skipped by operator during inspection |
| Why 3 | Operator negligence |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Skipped by operator during inspection due to Operator negligence |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Mould delay time controlling mechanism in moulding process, Feasibility to be checked | FNI | 10/06/2022 | 10/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | 100% inspection with gauge for available stock verification |
| Inspection Method | Other |
| Other Inspection Method | NA |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Inadequate controlling
mechanism for mould delay time in moulding
process 132_Occurance_Before.pdf |
| Occurance (After) |
Mould delay time controlling mechanism provided in moulding machine 132_Occurance_After.pdf |
| Outflow (Before) |
Curing defect was not defined in matrix at final stage 132_Outflow_Before.pdf |
| Outflow (After) |
Visual defect matrix updated for curing at dust lip at final
inspection stage. 132_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | NA |
12. Document Review
| Documents | WISOP |
| Specify Other Document | Defect Matrix |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | Parts found ok in 3 lot monitoring |