QFR No - 8000831275
Defect Details
| NC No. | 8000831275 |
| NC Date | 01/06/2023 |
| NC Submission Date | |
| Part No. | S1AB00612B |
| Part Name | ADJUSTER PLATED |
| Supplier Name & Code | 100782-NICE STEEL INDUSTRIES |
| ETL Plant | 1146-ETL Suspension Narasapura |
| Defect Details | WELDING NOT OK-IMPROPER WELDING (GAP) , EXTRA WELDING P |
1. Problem Description
| Defect Description | adjuster welding issues (improper welding (gap ) ) |
| Detection Stage | Receipt |
| Problem Severity | Safety |
| NG Quantity | 6036 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | 25w4rf2t3qmac05lbmkjdpe3.gif |
Supplier Communication Details
| Quality Head Email ID | ppc.nice@batragroup.biz |
| Plant Head/CEO Email ID | ho.nice@batragroup.biz |
| MD Email ID | hitesh@batragroup.biz |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2000
|
2000
|
1000
|
1000
|
0
|
6000
|
| Check Qty |
2000
|
2000
|
1000
|
1000
|
0
|
6000
|
| NG Qty |
5
|
8
|
0
|
0
|
0
|
13
|
| Scrap | 0 |
| Rework | 13 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100% VISUAL INSPECTION TO BE DONE |
3. Process Flow
| Process Flow Description |
|---|
| 10 RECEIVING INSPECTION 20 STORAGE 30 BLANKING 40 1st BENDING ( `U` BENDING) 50 FINAL BENDING ( ROUNDING ) 60 MIG WELDING 70 FLAIRING 1st 80 FLAIRING 2nd 90 ID SIZING 100 SIDE GRINDING & BUFFING 110 BROACHING 120 HEAD GRINDING 130 OUTSIDE MOVEMENT FOR PLATING 140 STORAGE & RQC INSP. OF PLATED MATERIAL 150 FINAL INSPECTION 160 PACKING & DISPATCH |
4. Process Details
| Process / Operation | WELDING |
| Outsource | No |
| Machine / Cell | MIG WELDING MACHINE |
| Machine / Cell No. | MACHINE NO 6,7 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Tool | NOZZELE TIP WAS NOT CLEAN | TIP CLEANIN G FREQUENCY WAS DEFINED | O |
| Man | UNTRAINED OPERATOR | OPERATOR WAS UNDER TRIAL | X |
| Method | SYATEM WAS NOT DEFINED FOR HANDLING OF OPERATOR TRIAL PARTS | PART FOUND NG DURING OPERATOR TRIAL | X |
| Material | MIG WIRE DIA WAS UNDER SIZE/ OVER SIZE | MIG WIRE DIA WAS OK AS PER DEFINED | O |
| Machine | MACHINE WAS NOT OK | MACHINE OK | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | VISUAL |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | IS:2500 |
7. Root Cause Analysis (Occurance)
| Why 1 | WELDING CRACK IN PART |
| Why 2 | WELDING MATERIAL NOT FILL COMPLETELY IN THE GAP |
| Why 3 | OPERATOR WAS SEMISKILLED |
| Why 4 | OPERATOR WAS UNDER TRIAL |
| Why 5 | |
| Root Cause (Occurance) | 1-OPERATOR WAS UNDER TRIAL 2- SYSTEM WAS NOT DEFINED TO HANDLING THE OPERATOR TRIAL PARTS |
Root Cause Analysis (Outflow)
| Why 1 | OK & NG PART MIXUP |
| Why 2 | SYSTEM WAS NOT DEFINED TO HALDING THE OPERATOR TRIAL PARTS |
| Why 3 | |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | SYSTEM WAS NOT DEFINED TO HALDING THE OPERATOR TRIAL PARTS |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | 100% VISLA INSPECTION TE BE STARTED | NICE | 06/06/2023 | 06/06/2023 | Completed |
| Occurance | LOCATION TO BE DEFINED FOR OPERATOR TRIAL PARTS | NICE | 06/06/2023 | 06/06/2023 | Completed |
| Occurance | OPERATOR OBSERVATION SYSTEM TO BE STARTED DURING TRIAL PERIOD | NICE | 06/06/2023 | 06/06/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100 % VISUAL INSPECTION |
| Inspection Method | Other |
| Other Inspection Method | OPL TO BE DISPLAYED |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
NO ANY WELDING AREA FOR UNDER TRIAL WELDER 463_Occurance_Before.jpg |
| Occurance (After) |
WELDING AREA MADE FOR UNDER TRIAL WELDER 463_Occurance_After.jpg |
| Outflow (Before) |
NO ANY SEPRATE AREA FOR OPERATOR TRIAL PARTS 463_Outflow_Before.jpg |
| Outflow (After) |
AREA MADE FOR OPERATOR TRIAL PARTS 463_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | OTHER WELDING PART - BOTTOM ACK |
12. Document Review
| Documents | WISOP |
| Specify Other Document | WI & OPL |
13. Effectiveness Of Action
| Reviewed Quantity | 500 |
| Reason for submission |