QFR No - 8000831090
Defect Details
| NC No. | 8000831090 |
| NC Date | 31/05/2023 |
| NC Submission Date | |
| Part No. | B2FP01013O |
| Part Name | HOLDER BRACKET FINISHED - REML |
| Supplier Name & Code | 100398-MANOJ INDUSTRIES |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | DAMAGES-AFTER 100% INSP. BH,PINHOLES,DENT,DAMAGE |
1. Problem Description
| Defect Description | Dent, & Blow holes observed on parts |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 25 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | qad@manojindustrieskop.com |
| Plant Head/CEO Email ID | foundry@manojindustrieskop.com |
| MD Email ID | mgnt@manojindustrieskop.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
1750
|
450
|
0
|
500
|
0
|
2700
|
| Check Qty |
1750
|
450
|
0
|
500
|
0
|
2700
|
| NG Qty |
18
|
13
|
0
|
7
|
0
|
38
|
| Scrap | 38 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% visual Inspection of All pipeline stock |
3. Process Flow
| Process Flow Description |
|---|
| casting ,VMC machining ,Slotting ,Final Inspection |
4. Process Details
| Process / Operation | casting ,VMC machining |
| Outsource | No |
| Machine / Cell | ENDURANCE CELL |
| Machine / Cell No. | VMC-14 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|
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 | Dent damage observed on casting |
| Why 2 | Casting dent observed at parting process |
| Why 3 | After parting parts not kept properly |
| Why 4 | operator keeps the parts in open bin from 2ft height |
| Why 5 | |
| Root Cause (Occurance) | operator keeps the parts in open bin from 2ft height |
Root Cause Analysis (Outflow)
| Why 1 | Dent damage observed on casting |
| Why 2 | skipped from final inspector |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | skipped from final inspector |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No |
| 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) |
After parting operation parts kept in open bin 456_Occurance_Before.png |
| Occurance (After) |
After parting parts kept in partitioned bin 456_Occurance_After.jpg |
| Outflow (Before) |
no Dot mark provided 456_Outflow_Before.jpg |
| Outflow (After) |
Dot mark provided 456_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Master cylinder,Calipers |
12. Document Review
| Documents | WISOP |
| Specify Other Document | Quality plan |
13. Effectiveness Of Action
| Reviewed Quantity | 100 |
| Reason for submission | NO damage observed in corrected lot |