QFR No - 8000791480
Defect Details
| NC No. | 8000791480 |
| NC Date | 15/06/2022 |
| NC Submission Date | |
| Part No. | S1AB00307B |
| Part Name | ADJUSTER POWDER COATED K0LA |
| Supplier Name & Code | 100973-ABHIVRDHI ENGINEERING PRIVATE |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | POWDER COATING NOT OK-POWDERCOATING PROBLEM |
1. Problem Description
| Defect Description | Powder Coating defects like paint bubble, paint dry, paint dust etc. and wrong supplier code (found V code instead of A code) |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 275 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | 0s4yuyooyw4vtdtqjaz2mq3a.jpg |
Supplier Communication Details
| Quality Head Email ID | rkhare@tesmomotorcast.com |
| Plant Head/CEO Email ID | harish.bala@tesmomotorcast.com |
| MD Email ID | svkallani@tesmomotorcast.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
275
|
0
|
0
|
0
|
2100
|
2375
|
| Check Qty |
275
|
0
|
0
|
0
|
2100
|
2375
|
| NG Qty |
275
|
0
|
0
|
0
|
0
|
275
|
| Scrap | 75 |
| Rework | 150 |
| Under Deviation | 50 |
| Containment Action |
|---|
| After powder coated 100% inspection |
3. Process Flow
| Process Flow Description |
|---|
| pdc - ,reming - od grinding, - debering - surface treatment - inspection - powder coated - packing. |
4. Process Details
| Process / Operation | Powder Coated |
| Outsource | Yes |
| Machine / Cell | booth 1 |
| Machine / Cell No. | 1 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | not proper spray | gauge | O |
| Method | Pre-Treatment process not done | system | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Gauge |
| Other Inspection Method | |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1 |
7. Root Cause Analysis (Occurance)
| Why 1 | Powder coating not ok |
| Why 2 | Powder not uniform on part |
| Why 3 | Powder electrostatic gun malfunctioning |
| Why 4 | Gun to earth continuity not good |
| Why 5 | Continuity pm not check |
| Root Cause (Occurance) | point not available in pm check sheet |
Root Cause Analysis (Outflow)
| Why 1 | powder coating not ok |
| Why 2 | Uncover part in final packing |
| Why 3 | 100 % inspection not happen after powder coating |
| Why 4 | Sample inspection process follow |
| Why 5 | Inspection system not ok |
| Root Cause (Outflow) | 100% inspection started |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Continuity checking from gun to hanger started | Rahul | 06/03/2023 | Completed | |
| Outflow | 100 % inspection started | Rahul | 06/03/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection after powder coating |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1 |
10. Evidance of Countermeasure
| Occurance (Before) |
Before powder coated 180_Occurance_Before.jpg |
| Occurance (After) |
after powder coated 180_Occurance_After.jpg |
| Outflow (Before) |
powder coated check 180_Outflow_Before.jpg |
| Outflow (After) |
100% inspection check 180_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | adjuster kola |
12. Document Review
| Documents | ControlPlan, PackingStd |
| Specify Other Document | process flow chart |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |