QFR No - 8000843758
Defect Details
| NC No. | 8000843758 |
| NC Date | 08/09/2023 |
| NC Submission Date | |
| Part No. | F800500507 |
| Part Name | UNDER BRACKET ASSEMBLY |
| Supplier Name & Code | 100060-A.G.TRANSMISSIONS |
| ETL Plant | 1117-ETL K-228/9 Suspension |
| Defect Details | PAINT PEEL OFF- |
1. Problem Description
| Defect Description | Under bracket powder coating peel off |
| Detection Stage | Customer End |
| Problem Severity | Aesthetic |
| NG Quantity | 80 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo | pb5pwowhm0lnevbbhi3i5h1c.pdf |
Supplier Communication Details
| Quality Head Email ID | agtransmissions@rediffmail.com |
| Plant Head/CEO Email ID | agforge@rediffmail.com |
| MD Email ID | agtransmissions@rediffmail.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
677
|
3346
|
0
|
1800
|
749
|
6572
|
| Check Qty |
677
|
3346
|
0
|
1800
|
749
|
6572
|
| NG Qty |
677
|
11
|
0
|
11
|
7
|
706
|
| Scrap | 0 |
| Rework | 706 |
| Under Deviation | 0 |
| Containment Action |
|---|
| AGT has recalled suspected lot i.e. 677 Nos. & remaining parts are kept on hold |
3. Process Flow
| Process Flow Description |
|---|
| Forging Incoming, Bracket Machining, Shaft Machining, Insert Pressing & welding, Shaft Machining, Assembly Welding, Powder Coating, Tapping, Fine Boring, Final Inspection |
4. Process Details
| Process / Operation | Powder Coating |
| Outsource | No |
| Machine / Cell | Powder Coating setup |
| Machine / Cell No. | Powder Coating |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | Operator unskilled | Skill Matrix available | O |
| Man | Operation skip by operator | Process flow followed by operator | O |
| Man | Assembly not dip properly | May assembly not dip properly. | O |
| Method | Inlet and Outlet FRL cleaning is not maintained | Inlet and Outlet FRL cleaning is maintained | O |
| Method | Pre Heating Not done | Pre Heating done | O |
| Method | Titration Not done | Titration done | O |
| Method | After PT process part not cleaning | After PT process part cleaning | O |
| Material | Alkaline Degresing Pointage | Alkaline Degresing Pointage ok | O |
| Material | Water ringing PH 2 no. | Water ringing PH 2 no. ok | O |
| Material | Activation PH | Activation PH ok | O |
| Material | Passivation Pointage | Passivation Pointage ok | O |
| Material | All titration solution not available | All titration solution available | O |
| Material | Higher / lower DFT | DFT IS OK | O |
| Machine | PM of PC gun not done | PM of PC gun done | O |
| Machine | Compressor not drain or dryer not working | Compressor is drain or dryer working | O |
| Machine | P.C machine programm change | P.C machine program not change (program passed protected) | O |
| Machine | Oven PM not done | Oven PM not done | O |
| Machine | TTR not ok | TTR not ok | X |
| Machine | Oil skimmer not working | Oil skimmer working | O |
| Machine | All timer not working | All timer working | O |
| Machine | All sensors are not working | All sensors are working | O |
| Machine | All timer Buzzers not working | All timer Buzzers working | O |
| Machine | All tank Air agitation | All tank Air agitation | O |
| Machine | Tank Temperature not OK | Tank Temperature ok | O |
| Machine | Oil not removed in the PT process | Oil removed in the PT process | O |
| Man | PT process inspection awareness | Aware of PT process inspection | O |
| Material | Degressing & derusting Pointage | Degressing & derusting Pointage ok | O |
| Material | Water rinsing PH 4 no. | Water rinsing PH 4 no.ok | O |
| Method | Powder Coating Gun cleaning frequency | Powder Coating Gun cleaning frequency flowed | O |
| Material | Phospating pointage | Phospating pointage ok | O |
| Method | Tank top up frequency not followed | Tank top up frequency followed | O |
| Material | Watrer Rinsing PH 7 | Watrer Rinsing PH 7 ok | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | By Hammering method |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | After 20 n |
7. Root Cause Analysis (Occurance)
| Why 1 | Peel off observed at customer end |
| Why 2 | Uneven Temp. in Oven. |
| Why 3 | TTR was done 6 months ago as per defined frequency. |
| Why 4 | |
| Why 5 | |
| Root Cause (Occurance) | TTR was done 6 months ago as per defined frequency. |
Root Cause Analysis (Outflow)
| Why 1 | Scratch test and rubber hammer test found ok |
| Why 2 | Both test carried out after 2hour of powder coating work |
| Why 3 | Lack of knowledge and awareness of the powder coating test |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Lack of knowledge and awareness of the powder coating test |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | TTR frequency modified to Per month. | QA | 21/09/2023 | 27/09/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | 100% Inspection started by Hammering method |
| Inspection Method | Other |
| Other Inspection Method | By Hammering & Visua |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100% |
10. Evidance of Countermeasure
| Occurance (Before) |
TTR was done 6 months ago as per defined frequency. 543_Occurance_Before.pdf |
| Occurance (After) |
TTR frequency decided one moth 543_Occurance_After.pdf |
| Outflow (Before) |
Inspection done after 20 no`s job by hammering and visual 543_Outflow_Before.xlsx |
| Outflow (After) |
100% hammering and inspection done 543_Outflow_After.xlsx |
11. Horizontal Deployment
| Horizontal Deployment Required | No |
| Applicable Machine / Model / Plant | only One Oven in company primises |
12. Document Review
| Documents | WISOP |
| Specify Other Document | TTR plan |
13. Effectiveness Of Action
| Reviewed Quantity | 150 |
| Reason for submission | 3 different lots of different model verified and found ok |