QFR No - 8000817842
Defect Details
| NC No. | 8000817842 |
| NC Date | 20/01/2023 |
| NC Submission Date | |
| Part No. | B2BK06823O |
| Part Name | CALIPER BODY-PAINTED - ATHER FR |
| Supplier Name & Code | 206460-TULJA ENTERPRISES |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | PANIT UNCOVER-AFTER 100% INSP. DUST, UNCOVER, ORANGE P |
1. Problem Description
| Defect Description | Paint uncover,dust,paint peel off |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 30 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | tuljaenterprises.e124@gmail.com |
| Plant Head/CEO Email ID | info@tulja.in |
| MD Email ID | tuljaenterprises.e124@gmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
30
|
0
|
0
|
0
|
0
|
30
|
| Check Qty |
30
|
0
|
0
|
0
|
0
|
30
|
| NG Qty |
30
|
0
|
0
|
0
|
0
|
30
|
| Scrap | 0 |
| Rework | 30 |
| Under Deviation | 0 |
| Containment Action |
|---|
| The touch up spray is under development. Once it will be developed, The issue be cured. Currently we are touching it up with existing paint. |
3. Process Flow
| Process Flow Description |
|---|
| Receipt of NG parts - Paint application and NG area - Baking - Visual inspection - Packing - Dispatch |
4. Process Details
| Process / Operation | Repainting |
| Outsource | No |
| Machine / Cell | Paint Booth |
| Machine / Cell No. | NA |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Sensitive Shade | The shade is sensitive at curved areas | X |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | L4 Operator Deployed |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
7. Root Cause Analysis (Occurance)
| Why 1 | The component geometry is difficult to cover with electrostatic gun. |
| Why 2 | The shade is sensitive |
| Why 3 | Paint not applied properly |
| Why 4 | Painter coverage was poor at curved area |
| Why 5 | L3 Operator deployed at inspection stage |
| Root Cause (Occurance) | Improper application of paint at curved and deep surface. |
Root Cause Analysis (Outflow)
| Why 1 | L3 operator was deployed |
| Why 2 | Inspector did not inspected properly |
| Why 3 | Operator did not inspected the curved and deep surface of the component. |
| Why 4 | Operator did not informed senior inspector |
| Why 5 | Senior operator was not inspecting the parts |
| Root Cause (Outflow) | L3 operator was deployed for inspection |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Conventional gun will used for coverage at deep surface. | Operation Head | 03/02/2023 | 03/02/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Additional inspector placed for a month at the inspection stage |
| 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) |
Uncover 339_Occurance_Before.jpg |
| Occurance (After) |
Covered with iwata gun 339_Occurance_After.jpg |
| Outflow (Before) |
Uncover 339_Outflow_Before.jpg |
| Outflow (After) |
Ok. 339_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | Paint Booth |
12. Document Review
| Documents | |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 250 |
| Reason for submission | Paint uncover 100% checked found ok |