QFR No - 8000808079
Defect Details
| NC No. | 8000808079 |
| NC Date | 17/10/2022 |
| NC Submission Date | |
| Part No. | S2HT68607B |
| Part Name | OUTER SPRING K23L |
| Supplier Name & Code | 101069-SAGAR SPRINGS PVT LTD |
| ETL Plant | 1116-ETL K-120 Suspension |
| Defect Details | HOOK MARK-TOUCHUP NOT OK |
1. Problem Description
| Defect Description | Powder coating observed not OK in almost all model & on daily basis. In K23L Outer spring supplied for expert, due to hook mark concern, end customer raising complaint on frequently. |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 28 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@sagarsprings.com |
| Plant Head/CEO Email ID | ajai.singh@sagarsprings.com |
| MD Email ID | sagar@sagarsprings.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1500
|
5000
|
0
|
1600
|
0
|
8100
|
| Check Qty |
1500
|
5000
|
0
|
1600
|
0
|
8100
|
| NG Qty |
28
|
450
|
0
|
100
|
0
|
578
|
| Scrap | 0 |
| Rework | 578 |
| Under Deviation | 0 |
| Containment Action |
|---|
| Segregation carried out at warehouse as well as FG and spring hook mark reworked |
3. Process Flow
| Process Flow Description |
|---|
| Coiling – Tempering – Grinding - Shot Pinning – Tempering – Scragging – Sq correction/ht checking –Pre treatment-Powder coating- Inspection-Dispatch |
4. Process Details
| Process / Operation | Inspection |
| Outsource | No |
| Machine / Cell | Inspection and touch up table |
| Machine / Cell No. | 130 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Improper hook | Found hook used are of appropriate design | O |
| Method | Spring not hanged properly | Spring are hanged properly on hanger and locked properly | O |
| Material | Hook get deformed while locking of spring | In case of using used hook, some time hook shape get deformed | X |
| Method | Used hook with powder used | Found hook used are bared not powder coated | O |
| Man | Loading person negligance | Found some loading operators not properly loading spring | 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 | Hook get deformed while locking of spring |
| Why 2 | Hook strength of some hooks get weakens because of excessive reuse |
| Why 3 | Used hook with more than 4 cycle get mixed |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | Used hook with more than 4 cycle get mixed with other hook |
Root Cause Analysis (Outflow)
| Why 1 | Spring is not hanged properly and locked properly |
| Why 2 | Loading operator negilgence |
| Why 3 | Absence of awareness in loading person |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Absence of awareness in loading person result in improper loading |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Proper arrangement of hook made to identify it burning frequency and it status | PC-Supervisor | 22/10/2022 | 22/10/2022 | Completed |
| Outflow | Refresher training will be given to loading operator for checking loading pattern and proper locking | PC-Supervisor | 19/10/2022 | 19/10/2022 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Proper visual inspection at loading stage |
| 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) |
Hook of more than 3 burnt get mix and deformed hook get used on line 287_Occurance_Before.pdf |
| Occurance (After) |
Hook are properly tracked and it freq could be identified it remain well arranged 287_Occurance_After.pdf |
| Outflow (Before) |
Lack of awareness to Loading person and Inspector 287_Outflow_Before.pdf |
| Outflow (After) |
Operators and inspectors are well understood and loading spring properly and identify hook mark defective spring 287_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applicable to all the powder coated springs |
12. Document Review
| Documents | ControlPlan, PFMEA, WISOP |
| Specify Other Document | OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 1000 |
| Reason for submission | Completed |