QFR No - 8000789262
Defect Details
| NC No. | 8000789262 |
| NC Date | 28/05/2022 |
| NC Submission Date | |
| Part No. | S2AB01907B |
| Part Name | ADJUSTER POWDER COATED |
| Supplier Name & Code | 100973-ABHIVRDHI ENGINEERING PRIVATE |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | POWDER COATING NOT OK-POWDER COATING DEFECT & UN COATED MIXUP |
1. Problem Description
| Defect Description | Major powder coating defects observed at receipt & during assembly stage. Same causing assembly line stoppage & increases rework activity. |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 1139 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | rkhare@tesmomotorcast.com |
| Plant Head/CEO Email ID | harish.bala@tesmomotorcast.com |
| MD Email ID | svkallani@tesmomotorcast.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1139
|
0
|
0
|
0
|
0
|
1139
|
| Check Qty |
1139
|
0
|
0
|
0
|
0
|
1139
|
| NG Qty |
439
|
0
|
0
|
0
|
0
|
439
|
| Scrap | 39 |
| Rework | 300 |
| Under Deviation | 100 |
| Containment Action |
|---|
| After powder coated 100% inspection |
3. Process Flow
| Process Flow Description |
|---|
| pdc, riming, od grinding, debering, inspection, & packing. |
4. Process Details
| Process / Operation | Powder Coated |
| Outsource | No |
| Machine / Cell | pdc 350t |
| Machine / Cell No. | pdc 350 t |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | not proper spray | gauge | O |
| Method | Pre-Treatment process not done | System | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 300 nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Powder coating not ok |
| Why 2 | Powder not uniform on part |
| Why 3 | Powder electrostatic gun malfunctioning |
| Why 4 | Gun to earth continuity not good |
| Why 5 | Continuity pm not check |
| Root Cause (Occurance) | point not available in pm check sheet |
Root Cause Analysis (Outflow)
| Why 1 | powder coating not ok |
| Why 2 | Uncover part in final packing |
| Why 3 | 100 % inspection not happen after powder coating |
| Why 4 | Sample inspection process follow |
| Why 5 | Inspection system not ok |
| Root Cause (Outflow) | 100% inspection started |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Continuity checking from gun to hanger started | Sachin | 01/01/2023 | 01/01/2023 | Completed |
| Outflow | 100 % inspection started | Rahul | 01/09/2022 | 01/01/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection after powder coating |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1 |
10. Evidance of Countermeasure
| Occurance (Before) |
adjuster without powder coated 153_Occurance_Before.jpg |
| Occurance (After) |
After powder coated 153_Occurance_After.jpg |
| Outflow (Before) |
visual not check 153_Outflow_Before.jpg |
| Outflow (After) |
After inspection 153_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | samath coating |
12. Document Review
| Documents | AuditCheckSheet, PackingStd |
| Specify Other Document | control plan |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |