QFR No - 8000846809
Defect Details
| NC No. | 8000846809 |
| NC Date | 29/09/2023 |
| NC Submission Date | |
| Part No. | B2FP05213O |
| Part Name | HOLDER BRACKET FINISHED-RE J1 FRONT |
| Supplier Name & Code | 201092-PRANEEL INDUSTRIES |
| ETL Plant | 1120-ETL K-226/2 Disc Brakes |
| Defect Details | NOT AS PER SPECIFICATION-PART REJECTED AFTER 100% INSPECTION AT E |
1. Problem Description
| Defect Description | Powder coating not ok |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 8 |
| Is Defect Repeatative? | Yes |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@praneelgroup.com |
| Plant Head/CEO Email ID | praneelindustries@rediiffmail.com |
| MD Email ID | anilpatil@praneelgroup.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
260
|
0
|
0
|
80
|
0
|
340
|
| Check Qty |
260
|
0
|
0
|
80
|
0
|
340
|
| NG Qty |
8
|
0
|
0
|
5
|
0
|
13
|
| Scrap | 13 |
| Rework | 0 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All WIP checked at all end . Defective parts rejected. |
3. Process Flow
| Process Flow Description |
|---|
| Powder Coating Process ( Outsourcing at Krishna Coating ) |
4. Process Details
| Process / Operation | Powder coating |
| Outsource | Yes |
| Machine / Cell | VMC Cell |
| Machine / Cell No. | 01 |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Man | No awareness to operator | New operator | X |
| Method | Wrong method of poweder coating | verified, found ok | O |
| Tool | Ventury Damaged | Verified , ventury found damaged | X |
| Machine | Low air pressure | Verified , air pressure found ok | O |
| Material | Wrong material used | Verified , Material as per specifications | 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 | Uncover issue observed in Holder bracket |
| Why 2 | Defective ventury observed in Powder coating Gun |
| Why 3 | Powder coating Gun not proper checked before powder coating process |
| Why 4 | Powder coating Operator has not gained sufficient knowledge for powder coating process |
| Why 5 | |
| Root Cause (Occurance) | New Manpower |
Root Cause Analysis (Outflow)
| Why 1 | Skipped from final inspection |
| Why 2 | New Manpower |
| Why 3 | Old manpower unplanned absenteeism |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Old manpower unplanned absenteeism |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Occurance | Immediate new ventury install in Powder coating Gun | Mr.Tosif | 16/10/2023 | 16/10/2023 | Completed |
| Occurance | PM check Sheet provided at Powder coating booth for coating gun checking and Cleaning | Mr.Tosif | 25/10/2023 | 25/10/2023 | Completed |
| Outflow | Training provided to Powder coating operator for powder coating gun checking and Cleaning | Mr. Tosif | 16/10/2023 | 16/10/2023 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | No |
| Change Details | No changes |
| 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) |
No checkpoint in PM Checksheet 559_Occurance_Before.pptx |
| Occurance (After) |
Checkpoint added in PM checksheet 559_Occurance_After.jpg |
| Outflow (Before) |
Skipped from final inspection 559_Outflow_Before.jpg |
| Outflow (After) |
Training & awareness given to final inspector 559_Outflow_After.jpg |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All Holder Brackets for Praneel Industries |
12. Document Review
| Documents | PMCheckSheet, InspCheckSheet |
| Specify Other Document | Q-Alert |
13. Effectiveness Of Action
| Reviewed Quantity | 50 |
| Reason for submission | No defect found in latest lot |