QFR No - 8000803123
Defect Details
| NC No. | 8000803123 |
| NC Date | 06/09/2022 |
| NC Submission Date | |
| Part No. | S2HT20503B |
| Part Name | OUTER SPRING J1A & J1D OP#2 |
| Supplier Name & Code | 101225-HELICAL SPRINGS |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | DULL PLATTING-DULL PLATING OBSERVED |
1. Problem Description
| Defect Description | J1A/D Outer Spring Dull Finish Observed after plating |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 41 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | ncpbku455mdtvzcmb0bisizg.png |
Supplier Communication Details
| Quality Head Email ID | ravindra@helicalsprings.in |
| Plant Head/CEO Email ID | shaikhmoin@helicalspeings.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 |
4000
|
0
|
0
|
0
|
2000
|
6000
|
| Check Qty |
4000
|
0
|
0
|
0
|
2000
|
6000
|
| NG Qty |
41
|
0
|
0
|
0
|
12
|
53
|
| Scrap | 53 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Check all material ETL end And Helical end |
3. Process Flow
| Process Flow Description |
|---|
| Raw Material Receipt & Inspection > Coiling>Stress Relieving-1>End Grinding>Shot Peening>Scragging>ID, Length & Angle checking>Stress Relieving-2>Surface Finish- Plating>Final Inspection/ PDI>Packing> Dispatch. |
4. Process Details
| Process / Operation | Plating |
| Outsource | Yes |
| Machine / Cell | NA |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Method | Due to Excess empty time, the chemical in the nickel tank freezed causing improper Air agitation | Chemical in the nickel tank freezed causing improper Air agitation | O |
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 | the chemical in the nickel tank freezed |
| Why 2 | improper Air agitation |
| Why 3 | Due to Excess empty time, |
| Why 4 | -- |
| Why 5 | -- |
| Root Cause (Occurance) | Due to Excess empty time, the chemical in the nickel tank freezed causing improper Air agitation |
Root Cause Analysis (Outflow)
| Why 1 | Operator not identified the dull plating |
| Why 2 | due to the similar appearance |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Operator not identified the dull plating due to the similar appearance |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | OK & NG sample photo displayed at inspection table. Any similar deviation comparison to NG sample will also be rejected | QA | 01/04/2023 | 01/04/2023 | Completed |
| Occurance | After start of the line, air agitation checked. For Shutdown more than 3-4 days, PM will be planned . | Production | 01/04/2023 | 01/04/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | OK & NG sample photo displayed at inspection table |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
10. Evidance of Countermeasure
| Occurance (Before) |
No Proper Agitation. 244_Occurance_Before.pdf |
| Occurance (After) |
Air Agitation Found Ok. During Start Of Process. 244_Occurance_After.jpg |
| Outflow (Before) |
Operator not identified the dull plating due to the similar appearance. 244_Outflow_Before.pdf |
| Outflow (After) |
OK & NG sample photo displayed at inspection table. Any similar deviation comparison to NG sample will also be rejected. 244_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Plating parts |
12. Document Review
| Documents | PMCheckSheet, WISOP |
| Specify Other Document | No |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | In Evidence of Countermeasure Occurrence Side Evidence of Before & After need to be Attach |