QFR No - 8000790951
Defect Details
| NC No. | 8000790951 |
| NC Date | 11/06/2022 |
| NC Submission Date | |
| Part No. | F2LY02502B |
| Part Name | SOCKET HEADED BOLT - RE J1A |
| Supplier Name & Code | 100846-SANGKAJ ENGINEERING PVT.LTD. |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | NOT AS PER SPECIFICATION-PLATING THICKNESS LESS |
1. Problem Description
| Defect Description | Zinc Plating Thickness Less |
| Detection Stage | Customer End |
| Problem Severity | Function |
| NG Quantity | 23200 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | vishwas@sangkaj.com |
| Plant Head/CEO Email ID | pardeshinr@sangkaj.com |
| MD Email ID | anirudh.2007@hotmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
24800
|
0
|
0
|
400
|
3700
|
28900
|
| Check Qty |
50
|
0
|
0
|
5
|
10
|
65
|
| NG Qty |
10
|
0
|
0
|
0
|
0
|
10
|
| Scrap | 10 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All finish stage material taken for plating rework from ETL and SEPL, as it is not possible to verify 100% for plating thickness |
3. Process Flow
| Process Flow Description |
|---|
| Raw material inward--wire draw--Forging--Rolling--Heat treatment--plating- final inspection and PDI--packing and dispatch |
4. Process Details
| Process / Operation | Plating process |
| Outsource | Yes |
| Machine / Cell | Outsource |
| Machine / Cell No. | Outsource |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | process parameters are not as per specification | validation check for corrected parameters | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | XRF inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Low thickness observed on plated components |
| Why 2 | Process done on parts as per regular lot size |
| Why 3 | Because of small parts its required different lot size & current supply |
| Why 4 | Proper validation not done for small parts |
| Why 5 | during validation thickness checked on regular DFT which shows OK reading |
| Root Cause (Occurance) | 1) Proper validation not done for small parts. 2) Parts checked on regular thickness tester. |
Root Cause Analysis (Outflow)
| Why 1 | Low thickness observed on plated components |
| Why 2 | Not detected by regular thickness tester ( DFT) |
| Why 3 | XRF thickness reading is less than regular thickness tester reading |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | XRF thickness reading is less than regular thickness tester reading |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Plating will done on Valid parameters & its records maintained as per requirements . | M/S Krishna Indstires | 13/06/2022 | 12/06/2022 | Completed |
| Outflow | checking done on XRF thickness tester before dispatch the material , | M/S Krishna Industires | 13/06/2022 | 12/06/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Plating thickness checking start with XRF on sampling basis |
| Inspection Method | Instrument |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 10nos |
10. Evidance of Countermeasure
| Occurance (Before) |
Validation not done properly 172_Occurance_Before.pptx |
| Occurance (After) |
Proper validation done for small parts 172_Occurance_After.pdf |
| Outflow (Before) |
Checking method by regular DFT meter 172_Outflow_Before.pdf |
| Outflow (After) |
Checking method change to XRF from regular DFT meter 172_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All small parts |
12. Document Review
| Documents | ControlPlan, WISOP, InspCheckSheet |
| Specify Other Document | Validation document |
13. Effectiveness Of Action
| Reviewed Quantity | 150 |
| Reason for submission | Ok |