QFR No - 8000789810
Defect Details
| NC No. | 8000789810 |
| NC Date | 02/06/2022 |
| NC Submission Date | |
| Part No. | B2GQ03323O |
| Part Name | M/CYL BODY RAW POW.COATED-RE J1C FRONT |
| Supplier Name & Code | 100204-KRISHNA COATING |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | POWDER COATING NOT OK-AFTER100%INSP.DUST,UNCOVER,BUBBLE |
1. Problem Description
| Defect Description | Dust and uncover |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 60 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qualitykrishnaassociates01@gmail.com |
| Plant Head/CEO Email ID | ravikrishnacoating@gmail.com |
| MD Email ID | krishnacoating@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
4448
|
0
|
0
|
0
|
0
|
4448
|
| Check Qty |
4448
|
0
|
0
|
0
|
0
|
4448
|
| NG Qty |
125
|
0
|
0
|
0
|
0
|
125
|
| Scrap | 0 |
| Rework | 125 |
| Under Deviation | 0 |
| Containment Action |
|---|
| before sampling basis Inspection done at inward stage. but currently we start 100 % raw material Inspection at inward inspection stage |
3. Process Flow
| Process Flow Description |
|---|
| Inward -100 % visual inspection - Pretreatment - Drying - Powder coating - Baking - final inspection - packing & dispatch |
4. Process Details
| Process / Operation | Powder Coating |
| Outsource | No |
| Machine / Cell | Powder coating line |
| Machine / Cell No. | Powder coating line |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Rusty material , oily , | Rusty material observed at inward stage | 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 | Bubble defect observed |
| Why 2 | White rust observe in master cylinder RE- J1C at inward stage |
| Why 3 | no 100 % visual inspection plan at inward stage |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | White rusty part observe at inward inspection stage |
Root Cause Analysis (Outflow)
| Why 1 | rusty material observed |
| Why 2 | Only inward inspection on sampling basis |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Rusty Material |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Now we started 100% visual inspection at inward stage | Ahok dabhade | 04/07/2022 | 05/07/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% visual Inspection at inward stage |
| Inspection Method | Other |
| Other Inspection Method | VIsual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
10. Evidance of Countermeasure
| Occurance (Before) |
only sampling basis inward inspection at inward stage 161_Occurance_Before.pdf |
| Occurance (After) |
Now Started 100 % visual inspection at inward stage ( as per sampling plan ) 161_Occurance_After.pdf |
| Outflow (Before) |
only sampling basis inward inspection at inward stage 161_Outflow_Before.pdf |
| Outflow (After) |
Now Started 100 % visual inspection at inward stage ( as per sampling plan 161_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | inward stage |
12. Document Review
| Documents | WISOP |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 1360 |
| Reason for submission | No rusty found in next 3 lot |