QFR No - 8000802401
Defect Details
| NC No. | 8000802401 |
| NC Date | 31/08/2022 |
| NC Submission Date | |
| Part No. | S2HT11807B |
| Part Name | OUTER SPRING _B104 E |
| Supplier Name & Code | 101225-HELICAL SPRINGS |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | POWDER COATING NOT OK-P.COATING ROUGHESS&SHSDE VERACTION |
1. Problem Description
| Defect Description | Powder coating Uncover & shade variation due to Over backing |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 190 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | ravindra@helicalsprings.in |
| Plant Head/CEO Email ID | shaikhmoin@helicalsprings.in |
| MD Email ID | ataneja@helicalsprings.in |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1500
|
0
|
0
|
0
|
2000
|
3500
|
| Check Qty |
1500
|
0
|
0
|
0
|
2000
|
3500
|
| NG Qty |
190
|
0
|
0
|
0
|
0
|
190
|
| Scrap | 0 |
| Rework | 190 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Check all material ETL end & helical end. |
3. Process Flow
| Process Flow Description |
|---|
| Raw Material Receipt & Inspection> Coiling > Stress Relieving > End Grinding > Shot Peening > Scragging > ID, Length & Angle checking > Surface Finish- Powder Coating > Final Inspection/ PDI > Packing > Dispatch |
4. Process Details
| Process / Operation | Powder Coating |
| Outsource | No |
| Machine / Cell | NA |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Machine | Machine check Sheet not followed | CLIT verified found Ok | O |
| Method | Improper Material handling | Material handling done as per process verified found ok | O |
| Man | unskilled Operator | Skill matrix checked found ok | O |
| Material | Material Grade | RMTC verified found ok | O |
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 | 1000/19 |
7. Root Cause Analysis (Occurance)
| Why 1 | Powder Coating Shade Varication |
| Why 2 | Imbalance mixing ratio of fresh & recycle powder |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Imbalance mixing ratio of fresh & recycle powder |
Root Cause Analysis (Outflow)
| Why 1 | Powder Coating Shade varicaton |
| Why 2 | PDIR done sampling basis |
| Why 3 | Not Detect in sampling |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Not Detect in sampling |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Mixing ratio of fresh & recycle powder defined: 80 - 20 % | Mr. Narayan Shedute | 30/09/2022 | 14/09/2022 | Completed |
| Outflow | Master samples & panels made | Mr.Anuj Shelke | 30/09/2022 | 14/09/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% inspection done before dispatch. |
| Inspection Method | Other |
| Other Inspection Method | Visual Inspection |
| Check Point at Final Inspection | No |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 1000/25 |
10. Evidance of Countermeasure
| Occurance (Before) |
Mixing ratio of fresh & recycle powder was 70- 30 % 236_Occurance_Before.pdf |
| Occurance (After) |
Mixing ratio of fresh & recycle powder defined: 80 - 20 % 236_Occurance_After.pdf |
| Outflow (Before) |
Criteria was not defined for shade 236_Outflow_Before.pdf |
| Outflow (After) |
Master samples & panels made 236_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | B104 Outer & B106 Big (Brass Gold Coated Part only.) |
12. Document Review
| Documents | WISOP |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | No Defect reported |