QFR No - 8000790294
Defect Details
| NC No. | 8000790294 |
| NC Date | 07/06/2022 |
| NC Submission Date | |
| Part No. | S1JL02405B |
| Part Name | PISTON ROD PLATED K0LA |
| Supplier Name & Code | 100953-PACE AUTOPARTS PRIVATE LIMITED |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | LENGTH OVERSIZE-TOTAL LENGTH OVERSIZE |
1. Problem Description
| Defect Description | Length Over Size |
| Detection Stage | Inprocess |
| Problem Severity | Fitment |
| NG Quantity | 140 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qa@paceautoparts.in |
| Plant Head/CEO Email ID | sudhakar.chavan@paceautoparts.in |
| MD Email ID | jadhav@paceautoparts.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
4200
|
0
|
10000
|
2520
|
0
|
16720
|
| Check Qty |
4200
|
0
|
10000
|
2520
|
0
|
16720
|
| NG Qty |
140
|
0
|
0
|
0
|
0
|
140
|
| Scrap | 0 |
| Rework | 0 |
| Under Deviation | 140 |
| Containment Action |
|---|
| All quantity available at end checked for reported concern issue & no any found defective quantity. |
3. Process Flow
| Process Flow Description |
|---|
| Cutting- CNC machining-I - Rough grinding-I -Rough grinding-II - CNC machining -II - Thread rolling- I- thread rolling-II - Semi finish grinding-Finish grinding - Hard chrome plating- Superfinishing process- Final inspection - packing- Dispatch |
4. Process Details
| Process / Operation | Packing |
| Outsource | No |
| Machine / Cell | Packing |
| Machine / Cell No. | packing-I |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Improper material handling | Improper material handling | O |
| Method | Multiple items handled same time at packaging | Multiple items handled same time at packaging | O |
| Method | Similar location for items | Similar location for items | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | 100 % box weight |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
7. Root Cause Analysis (Occurance)
| Why 1 | Multiple items handled same time at packaging |
| Why 2 | Similar locations for items |
| Why 3 | care not to be taken during packaging |
| Why 4 | Lack of awareness |
| Why 5 | |
| Root Cause (Occurance) | operator negligence |
Root Cause Analysis (Outflow)
| Why 1 | Lack of awareness |
| Why 2 | Negligence |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Negligence |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | We had started the box weight 200 %& displayed the weight chart at weighing machine | Store | 10/06/2022 | 07/06/2022 | Completed |
| Occurance | We had implemented the one item packaging at a single time & on only line single model will be placed for final inspection also. | Final inspection | 15/06/2022 | 10/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No any change in inspection system. |
| Inspection Method | Other |
| Other Inspection Method | 200 % box weight |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 % |
10. Evidance of Countermeasure
| Occurance (Before) |
Box weight done 100 % at the time of dispatch & multiple items for packaging at a time 163_Occurance_Before.jpg |
| Occurance (After) |
We have started the box weight 200 % at the time of dispatch & box weight chart displayed at weighing machine & On final inspection table single component will be checked & packed. 163_Occurance_After.jpg |
| Outflow (Before) |
Improper material handling 163_Outflow_Before.jpg |
| Outflow (After) |
Training given to operator regarding concern issue & proper material handling .. 163_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Horizontally deployed for all parts |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | DOC AUDIT |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Closed |