QFR No - 8000790195
Defect Details
| NC No. | 8000790195 |
| NC Date | 06/06/2022 |
| NC Submission Date | |
| Part No. | 260KN00107 |
| Part Name | RESERVOIR CAP POWDER COATED |
| Supplier Name & Code | 100204-KRISHNA COATING |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | POWDER COATING NOT OK-COATING UNCOVER,DUST,PIN HOLES |
1. Problem Description
| Defect Description | Powder Coating Uncover, dust |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 740 |
| 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 |
23450
|
0
|
0
|
0
|
0
|
23450
|
| Check Qty |
23450
|
0
|
0
|
0
|
0
|
23450
|
| NG Qty |
1782
|
0
|
0
|
0
|
0
|
1782
|
| Scrap | 0 |
| Rework | 1782 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Previously reservoir cap Coating on batch type line to resolve the uncover issue we shift coating from batch type to conveyor line And also dust mark issue also resolve because of close section of conveyor line. |
3. Process Flow
| Process Flow Description |
|---|
| Inward - Pretreatment - Drying - powder Coating- Baking- Final Inspection - 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 |
|---|---|---|---|
| Machine | 1) Over Coated Rod | Visual | 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 | Material Uncover issue? |
| Why 2 | Proper Earthing not get to the Part. |
| Why 3 | Over Coated rod |
| Why 4 | Rod used for coating 2 times |
| Why 5 | |
| Root Cause (Occurance) | Over Coated rod. |
Root Cause Analysis (Outflow)
| Why 1 | Found Over Coated Rod |
| Why 2 | We Shift Reservoir cap from batch type to conveyor line |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Over Coated Rod. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | We shift reservoir cap batch type coating to conveyor line | Mr. Ajim Patel | 06/07/2022 | 06/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | NA |
| 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) |
Batch type Before Loading Pattern for powder Coating 162_Occurance_Before.xlsx |
| Occurance (After) |
Conveyor line Loading Pattern for powder coating 162_Occurance_After.jpg |
| Outflow (Before) |
Batch type Before Loading Pattern for powder Coating 162_Outflow_Before.xlsx |
| Outflow (After) |
Conveyor line Loading Pattern for powder coating 162_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Conveyor line |
12. Document Review
| Documents | ControlPlan, ProcessFlowChart |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 12600 |
| Reason for submission | No defect found in Next 3 Lot |