QFR No - 8000792475
Defect Details
| NC No. | 8000792475 |
| NC Date | 23/06/2022 |
| NC Submission Date | |
| Part No. | S2BG00702B |
| Part Name | BRACKET UN P/C |
| Supplier Name & Code | 101032-ASM CASTINGS PRIVATE LIMITED ( |
| ETL Plant | 1143-ETL Suspension Halol, Vadodara |
| Defect Details | BUFFING DEFECT-BUFFING MARK,SCRATCH MARK |
1. Problem Description
| Defect Description | Buffing Mark |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 684 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo | zkxzdvg4s1fgjqi10txeucfj.jpg |
Supplier Communication Details
| Quality Head Email ID | quality@asmcastings.in |
| Plant Head/CEO Email ID | skaul@asmcastings.in |
| MD Email ID | rajiv@asmcastings.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
0
|
0
|
0
|
2200
|
1050
|
3250
|
| Check Qty |
0
|
0
|
0
|
2200
|
1050
|
3250
|
| NG Qty |
0
|
0
|
0
|
69
|
18
|
87
|
| Scrap | 0 |
| Rework | 87 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Re-Buffing done on Parts. |
3. Process Flow
| Process Flow Description |
|---|
| Incoming of R.M. - R.M. Melting - Die Casting - Lancering - Reamer - Drilling & Tapping - Buffing - Polishing - Inspection - Packing & PDI- Dispatch. |
4. Process Details
| Process / Operation | Buffing |
| Outsource | No |
| Machine / Cell | Machine Shop |
| Machine / Cell No. | Buffing Machine |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Operator not aware about Work | Skill Matrix to be verified for min. Level 2 | X |
| Method | Buffing Wheel Grade not Ok | Physical Verification for Appearance by Different Grade Wheel. | O |
| Machine | Scratch during Machining | Physical Verification | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | Buffing Marks on Bracket |
| Why 2 | Buffing Wheel Grade Not Adequate (120 No. while required 160 no. for Painted parts) |
| Why 3 | Process Validation not done as per Painted part |
| Why 4 | Paint At Customer End. |
| Why 5 | |
| Root Cause (Occurance) | Process Validation not done for Buffing Appearance. |
Root Cause Analysis (Outflow)
| Why 1 | Buffing Marks on Bracket |
| Why 2 | Skipped from Final Inspection |
| Why 3 | Limit Sample not provided for Buffing Marks. |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Limit Sample not provided for Buffing Marks. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | 01) Process Validation done for Buffing Appearance on painted parts. 02) Buffing Wheel Grade Changed from 120 to 160 no. 03) Control Plan updated for the buffing Wheel Grade. | Lalit Sharma | 15/07/2022 | 15/07/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | Visual Inspection as previous |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
Buffing Wheel Grade 120 No. 185_Occurance_Before.png |
| Occurance (After) |
Buffing Wheel Grade 160 No. 185_Occurance_After.png |
| Outflow (Before) |
Limit Sample was not provided 185_Outflow_Before.jpg |
| Outflow (After) |
Limit Sample Provided. 185_Outflow_After.jpeg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Buffing Machine |
12. Document Review
| Documents | ControlPlan, WISOP |
| Specify Other Document | Limit Sample |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission | Found ok and reduce visual defects |