QFR No - 8000834573
Defect Details
| NC No. | 8000834573 |
| NC Date | 26/06/2023 |
| NC Submission Date | |
| Part No. | 538LT00112 |
| Part Name | SILENT BLOCK PLATED |
| Supplier Name & Code | 101023-FORES ELASTOMECH INDIA PVT. LT |
| ETL Plant | 1118-ETL E-92,93 Suspension |
| Defect Details | DAMAGES-SHORTMOLDING:4NO,CHAMFERO/D DAMAGE:275NO |
1. Problem Description
| Defect Description | SHORT MOLDING & CHAMFER O/D DAMAGE |
| Detection Stage | Inprocess |
| Problem Severity | Aesthetic |
| NG Quantity | 279 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | malani.pritam@foresgroup.com |
| Plant Head/CEO Email ID | singh.barinder@foresgroup.com |
| MD Email ID | swamy.pj@foresgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
28000
|
0
|
0
|
35000
|
0
|
63000
|
| Check Qty |
28000
|
0
|
0
|
35000
|
0
|
63000
|
| NG Qty |
279
|
0
|
0
|
10
|
0
|
289
|
| Scrap | 289 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| 100 % Sorting done at customer end at ETL With special marking . 100 % Sorting done at M/s Fore End with Special identification on Box . |
3. Process Flow
| Process Flow Description |
|---|
| Receiving the material - (Inspect the Raw material , Inspect the insert, Inspect the Outer - Compound Batch - Moulding - Deflashing -Plating - Visual inspection - ID & Height inspection - Bond testing - Packaging -Dispatch. |
4. Process Details
| Process / Operation | Moulding |
| Outsource | No |
| Machine / Cell | Moulding |
| Machine / Cell No. | INJ-250T |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Wrong material used | verified the last six month data of hardness & Found okay | O |
| Machine | Weak joint of in metal to rubber. | NG part verify & Found not okay . | X |
| Tool | Tool not as per requirement . | Verified the tool as per PM inspection sheet & Found okay . | O |
| Man | Skipped from inspection | Inspection method not okay | X |
| Method | Insert & Outer loading method not oaky | verified the loading fixture & Found okay | O |
| Machine | Less or more temperature | verified the data for temperature & found okay . | O |
| Machine | Less or more cure time | verify the parameter & found okay . | 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 | Short Moulding |
| Why 2 | less material flow in mould cavity tool |
| Why 3 | material gate flow point broken by previous shot gate . |
| Why 4 | Gate is being broken from both end due to design constraint. |
| Why 5 | |
| Root Cause (Occurance) | Gate is being broken from both end due to design constraint. |
Root Cause Analysis (Outflow)
| Why 1 | Skipped form inspection. |
| Why 2 | defect not detect in inspection stage . |
| Why 3 | difficult to inspect this defect. |
| Why 4 | inspection method not okay. |
| Why 5 | |
| Root Cause (Outflow) | inspection method not okay. |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Gate point will check in every shot on rubber pad or part. | Mr Zukle | 26/06/2023 | 26/06/2023 | Completed |
| Outflow | Visual inspection will start on magnified glass With white background on table . | Mr motilal . | 26/06/2023 | 22/06/2023 | Completed |
| Occurance | Training given to operator . | Mr Zukle | 26/06/2023 | 26/06/2023 | Completed |
| Outflow | Awareness & training given to inspector | Mr motilal | 26/06/2023 | 26/06/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | N/A |
| 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) |
1.Gate is being broken from both end due to design constraint. 497_Occurance_Before.docx |
| Occurance (After) |
1.Gate point will check in every shot on rubber pad or part.
2.Training given to operator.
3.opl display at operation stage. 497_Occurance_After.pdf |
| Outflow (Before) |
inspection method not okay. 497_Outflow_Before.pptx |
| Outflow (After) |
1.Visual inspection will start on magnified glass With white background on table .
2.Opl display at inspection stage .
3.training & awareness given to inspector 497_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | Applicable for all part |
12. Document Review
| Documents | WISOP |
| Specify Other Document | N/A |
13. Effectiveness Of Action
| Reviewed Quantity | |
| Reason for submission |