QFR No - 8000790667
Defect Details
NC No. | 8000790667 |
NC Date | 13/06/2022 |
NC Submission Date | |
Part No. | 550MB07702 |
Part Name | SPACER TUBE - VE (115.5) |
Supplier Name & Code | 100756-BLUE STAR ENGINEERS |
ETL Plant | 1116-ETL K-120 Suspension |
Defect Details | EXCESS MATERIAL-GATE MARK ON FACE |
1. Problem Description
Defect Description | In Spacer tube (550MB07702) observed with excess high point at gate position & face parallisum observed up to 0.3 mm against requirement of 0.1mm. |
Detection Stage | Inprocess |
Problem Severity | Function |
NG Quantity | 1000 |
Is Defect Repeatative? | No |
Defect Sketch / Photo | qixcy22tqjkdv3zlpjwjrlqg.pdf |
Supplier Communication Details
Quality Head Email ID | kakade.dnyaneshwar@sanghavigroup.co |
Plant Head/CEO Email ID | prabhune.girish@sanghavigroup.co.in |
MD Email ID | sanghavi.rajesh@sanghavigroup.co.in |
2. Stock Details & action taken for NG parts
Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
---|---|---|---|---|---|---|
Total Qty |
20000
|
0
|
0
|
5000
|
0
|
25000
|
Check Qty |
20000
|
0
|
0
|
5000
|
0
|
25000
|
NG Qty |
1000
|
0
|
0
|
0
|
0
|
1000
|
Scrap | 0 |
Rework | 1000 |
Under Deviation | 0 |
Containment Action |
---|
Gate cutting. |
3. Process Flow
Process Flow Description |
---|
1)Raw Material Receiving & Storing - 2)Predrying/Pre Heating - 3)Injection moulding - 4)Deflashing & degating - 5)Final Inspection - 6)Packing & Storing - 7)Logistics and transport. |
4. Process Details
Process / Operation | Injection Moulding Process |
Outsource | No |
Machine / Cell | Injection Moulding Machine |
Machine / Cell No. | IMMH1017 |
5. Problem Analysis
Type | Possible Cause | Fact Verification | Jud |
---|---|---|---|
Man | Ineffective training | Gate point issue present in defect list | X |
Tool | Gate point provided at improper place. | Functional issues observed due to gate point. | 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 | Gate point issue observed resulting in funtional issue. |
Why 2 | Gate point mark observed at face due tool wear out. |
Why 3 | Tool wear out due to maintenance delay. |
Why 4 | Tool wear out faster than expected |
Why 5 | Gate point provided at sensitive point as compaired to function of part. |
Root Cause (Occurance) | Gate point provided at sensitive point as compaired to function of part. |
Root Cause Analysis (Outflow)
Why 1 | Gate point issue observed resulting in funtional issue. |
Why 2 | Degating Issue was not detected. |
Why 3 | Ineffective Training. |
Why 4 | |
Why 5 | |
Root Cause (Outflow) | Ineffective Training |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
---|---|---|---|---|---|
Occurance | Change in gate point position | Sarang Chandak | 04/07/2022 | 30/06/2022 | Completed |
9. Inspection Method After Customer Complaint
Change In Inspection System | Yes |
Change Details | 100% visual inspection with Marking(Blue marker) |
Inspection Method | Other |
Other Inspection Method | visual |
Check Point at Final Inspection | Yes |
Checking Freq. | 100% |
Sampling | No |
Sample Size | 1000 |
10. Evidance of Countermeasure
Occurance (Before) |
Three plate mould(Point Gate) 173_Occurance_Before.jpg |
Occurance (After) |
Two plate Mould(Tab gate) 173_Occurance_After.jpg |
Outflow (Before) |
Defect list 173_Outflow_Before.xlsx |
Outflow (After) |
Defect list change 173_Outflow_After.xlsx |
11. Horizontal Deployment
Horizontal Deployment Required | No |
Applicable Machine / Model / Plant | n |
12. Document Review
Documents | PMCheckSheet |
Specify Other Document | n |
13. Effectiveness Of Action
Reviewed Quantity | 1000 |
Reason for submission | Completed. |