QFR No - 8000788830
Defect Details
| NC No. | 8000788830 |
| NC Date | 25/05/2022 |
| NC Submission Date | |
| Part No. | 53BKZ00102 |
| Part Name | RUBBER BUSH |
| Supplier Name & Code | 101023-FORES ELASTOMECH INDIA PVT. LT |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | EXCESS MATERIAL- FLESHES |
1. Problem Description
| Defect Description | Flash in ID |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 19 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | 3jd0wsglcjllsqocql1hxmsz.jpg |
Supplier Communication Details
| Quality Head Email ID | malani.pritam@foresgroup.com |
| Plant Head/CEO Email ID | singh.barinder@foresgroup.com |
| MD Email ID | swamy.pj@foresgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
30000
|
0
|
0
|
6000
|
0
|
36000
|
| Check Qty |
30000
|
0
|
0
|
6000
|
0
|
36000
|
| NG Qty |
15
|
0
|
0
|
0
|
0
|
15
|
| Scrap | 0 |
| Rework | 15 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % Stock Verification at Fores End . |
3. Process Flow
| Process Flow Description |
|---|
| Rubber & Chemical - incoming inspection - Mixing & Rubber Compound - Hardness Inspection - Molding - Visual Inspection - Packing and Dispatch . |
4. Process Details
| Process / Operation | Rubber Moulding |
| Outsource | No |
| Machine / Cell | Moulding |
| Machine / Cell No. | Moulding |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Curing Time Less Or More | PLC controlled in Machine If parameter not okay then machine stop | X |
| Man | Skip From inspection | Not sufficient training to detect the potential failure . | O |
| Material | Wrong Material used | Last Six month MTC report verified material found okay | X |
| Machine | Curing Temperature is Less or more | PLC controlled in Machine If parameter not okay then machine stop | X |
| Tool | Tool PM Frequency | Less PM frequency | O |
| Material | Variation in chemical weight | Error proofing system for chemical weighing , so there is no chances of variation in chemical weight | X |
| Machine | Machine temperature Less or More | PLC controlled process in machine if any temp less or more then machine will stop . | X |
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 | Difficult to de flashing flash on part. |
| Why 2 | Due to heavy flash in Mould cavity |
| Why 3 | Flash cutting groove burnt. |
| Why 4 | Burnt groove not detect in tool PM. |
| Why 5 | Tool Frequency is Less |
| Root Cause (Occurance) | Tool PM frequency is less i.e after 20000 Shots . |
Root Cause Analysis (Outflow)
| Why 1 | Flash In ID |
| Why 2 | Skip from inspection |
| Why 3 | No sufficient training to detect the Quality issue . |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | No sufficient training to detect the Quality issue . |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Tool Pm frequency Is increase | Production Team | 19/05/2022 | 17/05/2022 | Completed |
| Outflow | Q gate Implement at Final inspection . | Amar Patil | 19/05/2022 | 17/05/2022 | Completed |
| Outflow | 100 % inspection marking Starting for Next one month . | Amar Patil | 19/05/2022 | 17/05/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | N/A |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 200 % |
10. Evidance of Countermeasure
| Occurance (Before) |
Tool PM frequency Is less. 149_Occurance_Before.xlsx |
| Occurance (After) |
Tool Pm Frequency Is Increase .
From 20000 Shots to 15000 Shots . 149_Occurance_After.xlsx |
| Outflow (Before) |
Inspection marking not available . 149_Outflow_Before.png |
| Outflow (After) |
Inspection marking Add for Next One month .
Q gate Implement at final inspection . 149_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Not applicable |
12. Document Review
| Documents | |
| Specify Other Document | N/A |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | 1. Tool PM frequency increased but validation report not attached. 2. Outflow side root cause not identified. Why inspector are not aware about potential failure?? 3. Countermeasure are not adequate i.e. no training given to operator, No OPL was displayed etc. 4. Q-gate implemented at FI stage, how it could be a root cause while already Visual inspection done at FI stage. 5. All relevant documents for all causes and actions are not attached. All evidences must be attached to confirm action and root cause. Zip file can be uploaded. Hence Upload multiple files in compressed form. 6. In Problem Analysis, fact verification found OK then remark 0 if fact verification found NG then remark X correct the 5th point . |